JP5098384B2 - Highly filled resin composition, method for producing tablet, and molded product comprising the same - Google Patents

Description

  The present invention has no mold corrosion, good flow, and the obtained molded product can exhibit the characteristics of the filler used at high strength with high efficiency. The present invention relates to a filled thermoplastic resin composition.

There have been many attempts to develop applications in fields where resinization has been difficult so far, and the required performance for resins tends to become more diversified and stricter.

  In recent years, due to the diversification of designs, the degree of freedom of the shape of molded products has been required. However, the metal used heretofore has a limit in the degree of freedom of the molded product. Therefore, a filler-reinforced thermoplastic resin has been studied for metal replacement. For example, the properties required for each application, such as thermal conductivity, high strength and high rigidity, and dimensional accuracy at high temperatures, are not satisfied by conventional filler-reinforced thermoplastic resins, and further improvements in properties are required. It has become like this. In particular, it has been demanded to increase the output of electrical control components such as a CPU of a personal computer, to maintain mechanical strength in a high temperature atmosphere due to heat when using laser light, and to reduce changes in characteristics due to temperature. In particular, since it is in a high-temperature atmosphere, a method for imparting heat dissipation properties to a resin has been proposed.

  Demand for polyarylene sulfide (hereinafter sometimes abbreviated as PAS) represented by polyphenylene sulfide (hereinafter also abbreviated as PPS) is high because of its heat resistance and ease of high filler filling. Is also expanding.

  However, since PAS has a high melting point, it has a problem that volatile components are likely to be generated due to high melt processing temperature and use temperature. Since the generation of volatile components causes mold corrosion during melt molding and malfunction when electronic parts are used, reduction of volatile gas components is strongly desired. Further, the conventional PAS has a relatively large amount of metal due to its manufacturing method, which contributes to lowering the dielectric breakdown voltage of the molded product, and may limit the application to the electrical case use. Therefore, there is a high demand for PAS with a small amount of volatile components and contained metals.

  As a specific method for producing this PAS, a method of reacting an alkali metal sulfide such as sodium sulfide with a polyhaloaromatic compound such as p-dichlorobenzene in an organic amide solvent such as N-methyl-2-pyrrolidone is proposed. This method is widely used as an industrial production method of PAS. However, this production method requires the reaction to be carried out under high temperature, high pressure, and strong alkaline conditions, and further requires an expensive high-boiling polar solvent such as N-methylpyrrolidone. However, it has a problem that it requires a large amount of process cost.

  Furthermore, since the polymerization reaction is a desalting polycondensation mechanism, a large amount of by-product salt such as sodium chloride is generated. Therefore, a by-product salt removal step is necessary after the polymerization reaction, but it is difficult to completely remove the by-product salt by ordinary treatment, and the commercially available general-purpose PPS product has an alkali metal content of about 1000 to 3000 ppm. Contained. Thus, when the alkali metal salt remains in the produced polymer, there arises a problem that physical properties such as electrical characteristics are lowered. Therefore, when an attempt is made to apply a molded article using such polyarylene sulfide as a raw material to the field of electric / electronic parts, the deterioration of the electric characteristics due to the alkali metal in the polyarylene sulfide becomes a major obstacle.

  The polyarylene sulfide obtained by this method is a polymer having a large molecular weight distribution, containing a large amount of low molecular weight components, having a very high degree of dispersion represented by the ratio of the weight average molecular weight to the number average molecular weight. For this reason, when used for molding processing, sufficient mechanical properties are not exhibited, and there are problems such as a large amount of gas components when heated and a large amount of eluted components when in contact with a solvent. In order to improve these problems, for example, a step of forming a cross-linked structure and increasing the molecular weight by performing a gas phase oxidation treatment in an oxidizing atmosphere such as in the air is required, and the process becomes more complicated. The productivity has been reduced (for example, see Patent Document 1).

  As a method for improving one of the problems of the PAS, that is, the PAS having a large amount of low molecular weight components and a wide molecular weight distribution, a mixture of PAS containing impurities is in a state higher than the minimum temperature at which the PAS forms a molten phase. Then, a method of purifying impurities by subjecting them to thermal extraction by phase separation into a polymer melt phase containing PAS and a solvent phase mainly, or a method of precipitating and recovering a granular polymer after cooling is proposed. ing. In these methods, impurities are extracted by the heat extraction effect, so it is expected that the metal content of PAS is reduced and the molecular weight distribution is narrowed, but the effect is insufficient, and an expensive organic solvent is used. The process was complicated due to the method (for example, Patent Documents 2 and 3).

  As another method for improving the above-mentioned problem, that is, PAS having a large amount of low molecular weight components and a wide molecular weight distribution, the sulfur source and the dihaloaromatic compound in an organic polar solvent at a temperature of 220 to 280 ° C. The ratio Mw / Mn of the weight average molecular weight Mw and the number average molecular weight Mn produced is characterized in that the PAS obtained by reacting for 1 to 2 hours is washed with an organic polar solvent at a temperature of 100 to 220 ° C. PASs in the range of ~ 5 are disclosed. In the production of the PAS, a low molecular weight distribution PAS is obtained by removing low molecular weight components by washing with an organic solvent at a high temperature, so that the yield of PAS is low, and the most dispersed is obtained. Even with a low degree of PAS, Mw / Mn = 2.9 and the effect was insufficient. Furthermore, in this method, since a large amount of expensive lithium compound is used in the polymerization of PAS, there are many problems to be solved, such as poor economic efficiency and lithium remaining in PAS. 4).

  As a method for improving the insufficient molecular weight distribution of PAS, a PAS obtained by polymerizing an alkali metal sulfide and / or alkaline earth metal sulfide and a polyhalogenated aromatic compound in an aprotic organic solvent is used. Into a polymerization solution containing a polymerization reaction product, water is added in an amount of 5 to 50% by weight of the total solution, and an inorganic and / or organic acid is added so that the polymerization solution becomes acidic, and the PAS polymerization reaction product in the solution is added. Discloses a PAS obtained by a production method characterized in that a solvent phase and a polymer melt phase are phase-separated at a temperature higher than the minimum temperature at which the polymer phase forms a melt phase, and the polymer melt phase is recovered. According to this method, it can be expected to obtain a PAS having a narrow molecular weight distribution with a dispersity Mw / Mn of about 1.9. In this method, however, a PAS having a wide molecular weight distribution is extracted in a molten solution state at high temperature and high pressure. Is used to separate a large amount of low molecular weight components from PAS, the process is complicated, and the yield of PAS obtained is as low as 80% or less, and the lithium compound is expensive in the polymerization of PAS. However, there remains a problem that there is a concern that this may remain in the polymer (for example, Patent Document 5).

  Further, as a method for producing a PAS having a narrow molecular weight distribution, a method in which a cyclic arylene sulfide oligomer is heated and subjected to ring-opening polymerization under an ionic ring-opening polymerization catalyst is disclosed. In this method, unlike Patent Documents 2 and 3, it can be expected to obtain a PAS having a narrow molecular weight distribution without performing a complicated organic solvent washing operation. However, in this method, since a sulfur alkali metal salt such as a sodium salt of thiophenol is used as a ring-opening polymerization catalyst in the synthesis of PAS, there is a problem that a large amount of alkali metal remains in the obtained PAS. Further, in this method, when an attempt is made to reduce the residual amount of alkali metal in PAS by reducing the amount of ring-opening polymerization catalyst used, there is a problem that the molecular weight of the resulting PAS becomes insufficient. (For example, patent documents 6 and 7).

  The problem of PAS obtained by the above method, that is, a method for reducing the residual amount of alkali metal in PAS, is a PAS in which a cyclic aromatic thioether oligomer is subjected to ring-opening polymerization in the presence of a polymerization initiator that generates sulfur radicals by heating. A manufacturing method is disclosed. In this method, since a nonionic compound is used as a polymerization initiator, it is considered that the alkali metal content of the obtained PAS is reduced. However, the glass transition temperature of the polyphenylene sulfide obtained by this method is as low as 85 ° C., which is because the molecular weight is low and the polyphenylene sulfide contains a large amount of low molecular weight components and has a wide molecular weight distribution. It was insufficient in terms of distribution. Furthermore, although there is no disclosure about the weight reduction rate when the obtained polyphenylene sulfide is heated in the method, the polymerization initiator used in the method has a lower molecular weight than polyphenylene sulfide and also has poor thermal stability. When polyphenylene sulfide obtained by this method is heated, a large amount of gas is generated, and there is a concern that molding processability is poor (for example, Patent Document 8).

  In the ring-opening polymerization in the PAS production methods of Patent Documents 6 to 8, it is preferable to use a high-purity cyclic polyarylene sulfide oligomer substantially free of linear polyarylene sulfide as the monomer source. Therefore, only a very small amount of linear polyarylene sulfide is allowed. In general, since cyclic oligomers are obtained as a mixture with a large amount of linear oligomers, a high degree of purification operation is required to obtain a high-purity cyclic product, which increases the cost of the resulting PAS. In ring-opening polymerization, there has been a demand for a method that allows a mixture of a cyclic body and a linear body to be used as the monomer source.

Also known is a PPS polymerization method in which a mixture of cyclic PPS and linear PPS is heated as a monomer source (Non-patent Document 1). This method is an easy polymerization method for PPS, but the resulting PPS has a low degree of polymerization and is not suitable for practical use. Although this document discloses that the degree of polymerization can be improved by increasing the heating temperature, it still does not reach a molecular weight suitable for practical use, and in this case, the formation of a crosslinked structure is not achieved. It has been pointed out that only PPS having inferior thermal properties cannot be obtained, and a high-quality PPS polymerization method more suitable for practical use has been desired.
Japanese Examined Patent Publication No. 45-3368 (7th to 10th pages) Japanese Patent Publication No. 1-25493 (page 23) Japanese Patent Publication No. 4-55445 (pages 3-4) JP-A-2-182727 (pages 9-13) JP-A-9-286860 (pages 5-6) Japanese Patent No. 3216228 (pages 7 to 10) Japanese Patent No. 3141459 (pages 5-6) US Pat. No. 5,869,599 (pages 27-28) US Pat. No. 3,793,256 (page 2) JP-A-3-41152 (Claims) JP 2000-246733 A (page 4) Polymer, vol. 37, no. 14, 1996 (pages 3111-3116)

  The present invention has no mold corrosion, good flow, and the obtained molded product can exhibit the characteristics of the filler used at high strength with high efficiency. It is an object to provide a filled thermoplastic resin composition and a molded product thereof.

As a result of intensive studies to solve the above problems, the present inventors have reached the present invention.
That is, the present invention
(1) When the sum of (a) and (b) is 100% by volume, (a) the weight average molecular weight (Mw) is 10,000 or more, and the dispersity represented by the weight average molecular weight / number average molecular weight (Mn) is 2 A filler high-filling resin composition comprising 5 to 50% by volume of polyarylene sulfide of 5 or less and (b) 95 to 50% by volume of an inorganic filler ,
(A) Polyarylene sulfide is
(I) It is obtained by melting and heating a cyclic polyarylene sulfide mixture represented by the following general formula (1),
(Ii) the alkali metal content is 100 ppm or less,
(Iii) The lactone type compound in the generated gas component when heated at 320 ° C. for 60 minutes in a non-oxidizing atmosphere is 500 ppm or less based on the weight of the polyarylene sulfide, and the aniline type compound is 300 ppm or less based on the weight of the polyarylene sulfide. A filler highly filled resin composition,

(M may be an integer of 4 to 20, m may be a mixture of 4 to 20)
( 2 ) The high filler filling according to (1), wherein (a) polyarylene sulfide obtained by melting and heating the cyclic polyarylene sulfide mixture in the absence of an ionic ring-opening polymerization catalyst is used. Resin composition,
(3) (b) The ratio (D90 / D10) of the 90% cumulative particle size (D90) and the 10% cumulative particle size (D10) obtained from the cumulative particle size distribution curve of the inorganic filler is 10 or more. The filler highly filled resin composition according to the above (1) or (2) ,
( 4 ) The highly filled resin according to any one of the above (1) to ( 3 ), wherein the cyclic polyphenylene sulfide mixture represented by the following general formula (1) and (b) an inorganic filler are melted and heated. Production method of the composition,

( 5 ) Further, (c) one or more of fatty acid metal salts, ester compounds, amide group-containing compounds, epoxy compounds, and phosphate esters are added to a total amount of 100 parts by weight of (a) and (b). The filler high-filling resin composition according to any one of (1) to ( 3 ), wherein 0.5 to 10 parts by weight of the filler is blended.
( 6 ) Manufacture of a tablet comprising a highly filled resin composition, wherein the highly filled resin composition according to any one of (1) to ( 3 ) and ( 5 ) above is compression-molded into tablets. Method,
( 7 ) A molded article obtained by injection molding the highly filled resin composition according to any one of (1) to ( 3 ) and ( 5 ) above.

  The present invention is capable of exhibiting the properties of fillers used with high strength, with good flowability, and good flow, while there is no mold corrosion during molding and high filler filling. Thus, it becomes possible to obtain a highly filled thermoplastic resin composition and a molded product thereof which could not be obtained conventionally.

  Hereinafter, the present invention will be described in detail.

(1) Polyarylene sulfide (PAS)
Representative examples of PAS include PPS, polyphenylene sulfide sulfone, polyphenylene sulfide ketone, random copolymers thereof, block copolymers, and mixtures thereof, among which PPS is particularly preferably used. PPS used in the highly filled resin composition of the present invention is a polymer containing 70 mol% or more, more preferably 90 mol% or more of the repeating unit represented by the structural formula (2), and the above repeating unit If it is less than 70 mol%, the heat resistance is impaired.

  Further, PPS can constitute less than 30 mol% of the repeating units with repeating units having the following structural formula.

  The molecular weight of the PAS of the present invention is 10,000 or more, preferably 15,000 or more, more preferably 18,000 or more in terms of weight average molecular weight. When the weight average molecular weight is less than 10,000, mechanical properties such as strength and toughness are deteriorated. Although there is no restriction | limiting in particular in the upper limit of a weight average molecular weight, Less than 1,000,000 can be illustrated as a preferable range, More preferably, it is less than 500,000, More preferably, it is less than 200,000. Balance between mechanical properties and mechanical properties.

  The dispersion of the molecular weight distribution of PAS in the present invention, that is, the dispersity represented by the ratio (Mw / Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) is 2.5 or less, preferably 2.3. Below, it is more preferably 2.1 or less, particularly preferably 2.0 or less. When the degree of dispersion exceeds 2.5, the amount of low molecular weight components contained in PPS tends to increase, and this is due to an increase in the amount of volatile gas components generated during molding, resulting in mold deposits and molded products. It tends to be a factor of characteristic deterioration due to voids.

  The weight average molecular weight and the number average molecular weight can be calculated, for example, in terms of polystyrene by gel permeation chromatography (GPC) which is a kind of size exclusion chromatography (SEC).

  Moreover, although there is no restriction | limiting in particular in the melt viscosity of PAS of this invention, Usually, the range whose melt viscosity is 5 to 10,000 Pa.s (300 degreeC, shear rate 1000 / sec) can be illustrated as a preferable range. The PAS of the present invention is characterized by being higher in purity than the conventional one, and the alkali metal content as an impurity is preferably 100 ppm or less, more preferably 50 ppm or less, still more preferably 30 ppm or less, and even more preferably 10 ppm or less. It is. When the alkali metal content exceeds 100 ppm, there is an increased possibility that the resin molded product application is restricted, for example, the melt moldability is lowered or the reliability in an application requiring high electrical insulation characteristics is lowered. Here, the alkali metal content of PAS in the present invention is a value calculated from, for example, the amount of alkali metal in ash, which is a residue obtained by baking PAS using an electric furnace or the like. It can be quantified by analyzing by an atomic absorption method.

  The alkali metal refers to lithium, sodium, potassium, rubidium, cesium, and francium belonging to Group IA of the Periodic Table, but the PAS of the present invention preferably does not contain sodium as the alkali metal. When an alkali metal is contained, it tends to adversely affect the electrical characteristics and thermal characteristics of PAS. In addition, there is a possibility that the amount of eluted metal when PAS comes into contact with various solvents is increased, and when PAS contains lithium, this adverse effect becomes strong because lithium is a metal that is easily eluted. By the way, among various metal species, compared to metal species other than alkali metals, such as alkaline earth metals and transition metals, alkali metals tend to have a strong influence on the electrical properties, thermal properties, and metal elution amount of PAS. is there. Therefore, it is speculated that among various metal species, the properties of a molded product obtained by adding a filler can be improved by controlling the alkali metal content within the above range. Furthermore, among alkali metals, in the polymerization of PAS, alkali metal sulfides typified by sodium sulfide are most commonly used, and molded products obtained by adding filler by setting the sodium content within the above range. Guess that the quality can be improved.

  The PAS used in the present invention preferably contains substantially no halogen other than chlorine, that is, fluorine, bromine, iodine, or astatine. When the PAS of the present invention contains chlorine as a halogen, it is stable in the temperature range where PAS is usually used. Therefore, even if a small amount of chlorine is contained, there is little influence on the mechanical properties of the PAS. When contained, these unique properties tend to deteriorate the properties of PAS, such as electrical properties and residence stability. When the PAS of the present invention contains chlorine as a halogen, the preferred amount is 1% by weight or less, more preferably 0.5% by weight or less, and still more preferably 0.2% by weight or less. The amount of reactive gas generated is reduced, melt moldability and mold corrosion under the use environment of the product are reduced, and electrical characteristics and retention stability tend to be better.

  Another feature of the PAS of the present invention is that the amount of lactone type compound and / or aniline type compound generated when heated is remarkably small. Examples of the lactone type compound include β-propiolactone, β-butyrolactone, β-pentanolactone, β-hexanolactone, β-heptanolactone, β-octanolactone, β-nonalactone, and β-decalactone. , Γ-butyrolactone, γ-valerolactone, γ-pentanolactone, γ-hexanolactone, γ-heptanolactone, γ-octalactone, γ-nonalactone, γ-decalactone, δ-pentanolactone, δ-hexa Nolactone, δ-heptanolactone, δ-octanolactone, δ-nonalactone, δ-decalactone, etc. can be exemplified, and aniline type compounds include aniline, N-methylaniline, N, N-dimethylaniline, N -Ethylaniline, N-methyl-N-ethylaniline, 4-chloro-aniline, 4-chloro-N-methyl Niline, 4-chloro-N, N-dimethylaniline, 4-chloro-N-ethylaniline, 4-chloro-N-methyl-N-ethylaniline, 3-chloro-aniline, 3-chloro-N-methylaniline, Examples include 3-chloro-N, N-dimethylaniline, 3-chloro-N-ethylaniline, 3-chloro-N-methyl-N-ethylaniline and the like. Generation of lactone-type compounds and / or aniline-type compounds when heated causes factors such as foaming and mold contamination during melt molding, not only deteriorating melt moldability, but also electrical properties in the subsequent product use environment. The amount of lactone type compound is preferably 500 ppm or less, more preferably less than 500 ppm, more preferably based on the weight of the PAS resin before heating. 300 ppm, more preferably 100 ppm or less, and even more preferably 50 ppm or less is desirable. Similarly, the amount of aniline type compound generated is preferably 300 ppm or less, more preferably 100 ppm, still more preferably 50 ppm or less, and even more preferably 30 ppm or less. In addition, as a method of evaluating the amount of lactone type compound and / or aniline type compound generated when PAS is heated, the gas generated when treated at 320 ° C. for 60 minutes in a non-oxidizing atmosphere is gas chromatographed. Divide and quantify.

(2) Production method of PAS The weight average molecular weight (Mw) of the present invention is 10,000 or more, and the degree of dispersion represented by weight average molecular weight / number average molecular weight (Mn) is 2.5 or less, preferably an alkali metal. As a method for producing PPS, the content of which is 100 ppm or less, a cyclic polyphenylene sulfide compound represented by the following general formula (1) is melt-heated and a high degree of polymerization having a weight average molecular weight of 10,000 or more In this method, the PAS of the present invention having the above-described characteristics can be obtained.

(3) Cyclic PAS compound As the cyclic PAS compound of the present invention, a cyclic PAS compound represented by the following general formula (1) and represented by an integer of m = 4 to 20 can be used. A mixture of 20 may be used.

(M may be an integer of 4 to 20, m may be a mixture of 4 to 20)

  The repeating unit m in the above formula is an integer of 4 to 20, preferably 4 to 15, and more preferably 4 to 12.

  In addition, although a single cyclic PAS having a single m has a difference in easiness of crystallization, since it is obtained as a crystal, the melting temperature becomes high, and therefore the temperature when converted to a high degree of polymerization tends to increase. Show. On the other hand, in the case of a mixture having different m, the melting temperature is lower than that of a simple cyclic PAS, and the temperature at the time of conversion to a high molecular weight body can be reduced. Due to this feature, even if there is no polymerization initiator containing an alkali metal, the degree of polymerization proceeds rapidly, and side reactions at the time of increasing the degree of polymerization are further suppressed. It becomes possible to manufacture a PAS resin with a small amount of gas components.

  For example, m = 6 cyclic PAS alone (cyclohexa (p-phenylene sulfide)) has a high melting point of 348 ° C., so that the cyclic product has a high molecular weight unless the heating temperature for melting is increased. There is a problem of not. Therefore, a method in which the cyclic PAS compound is dissolved in a solvent to be dissolved and converted into a high molecular weight body, and the crystallized cyclic PAS alone is once melted at a melting point or higher, and then rapidly cooled to suppress crystallization and to be amorphous. Thereafter, a method of converting to a high degree of polymerization or a method of setting the premelter to be equal to or higher than the melting point of the cyclic PAS alone, melting only the cyclic PAS alone in the premelter, and supplying the melt as a melt can be employed.

  Due to the characteristics of the cyclic PAS compound, the cyclic PAS compound used in the present invention is preferably a cyclic PPS compound having a different m from the viewpoint of easy high molecular weight and easy production.

  The content of cyclic PAS of m = 6 with respect to the cyclic PAS compound is preferably less than 50 wt%, more preferably less than 30 wt%, more preferably less than 10 wt% (m = 6 cyclic PAS alone (weight) ) / (Cyclic PAS compound (weight) × 100).

  The ratio of each different m in the cyclic PAS compound is not particularly limited, but in order to achieve the effect of the present invention, the cyclic PAS alone having the highest melting point and easy to crystallize among the cyclic PAS compounds. Is preferably less than 50% by weight, more preferably 30% by weight, particularly preferably less than 10% by weight (m = 6 cyclic PAS (weight) / (cyclic PAS mixture (weight) × 100)). Here, the content of m = 6 cyclic PAS alone in the cyclic PAS mixture is attributed to the compound having a PAS structure when the cyclic PAS mixture is divided into components by high performance liquid chromatography equipped with a UV detector. The ratio of the peak area attributed to a single cyclic PAS with m = 6 to the total peak area is as follows: Both are compounds having a PAS structure, for example, a cyclic PAS compound or a linear PAS, and a compound having a structure other than PAS in its part (for example, as a terminal structure) also belongs to the compound having a PAS structure referred to herein. In addition, the qualitative characteristics of each peak divided into components by this high performance liquid chromatography can be obtained by separating each peak by preparative liquid chromatography and performing an absorption spectrum or mass analysis in infrared spectroscopic analysis.

  Such a cyclic PAS compound can be obtained by obtaining a PAS mixture containing PAS and a cyclic PAS compound by a known PAS production method and then extracting the cyclic PAS compound from the PAS mixture. The manufacturing method will be described below.

(4) Method for Producing PAS Mixture as Raw Material for Cyclic PAS Compound As a method for producing a PAS mixture, a known technique can be used, for example, a polyhalogenated aromatic compound represented by at least p-dichlorobenzene, A mixture containing an alkali metal sulfide typified by sodium sulfide and an organic polar solvent typified by N-methyl-2-pyrrolidone is heated to prepare a reaction solution containing a PAS mixture and an alkali metal halide. Examples thereof include a method of obtaining a PAS mixture (PAS and cyclic PAS compound) by treating the liquid with water or the like, and a method of obtaining a PAS mixture by oxidative polymerization of diphenyl disulfides or thiophenols. However, since the cyclic PAS compound generally contained in the PAS mixture generally obtained by these methods is as low as less than 5% by weight, in order to obtain a PAS mixture containing 5% by weight or more of the cyclic PAS compound, for example, polymerization of the PAS mixture is performed. In this case, a special method such as using a large amount of a polymerization solvent is necessary, and it is economically disadvantageous to obtain a large amount of PAS mixture efficiently by such a method, and it is difficult to establish it industrially. .
Other methods for producing the PAS mixture include, for example, polyhalogenated aromatic compounds represented by at least p-dichlorobenzene, alkali metal sulfides represented by sodium sulfide, and N-methyl-2-pyrrolidone. At least granular PAS and a PAS mixture other than granular PAS, organic polar solvent, water, and alkali halide obtained by heating and polymerizing the mixture containing the organic polar solvent A preferred example is a method of obtaining a PAS mixture from a recovered slurry obtained when granular PAS is removed from a reaction solution containing a metal salt. Here, granular PAS refers to a PAS component that can be recovered with a standard sieve (80 mesh sieve) having an average aperture of 0.175 mm. The PAS mixture obtained by this method contains a large amount of low molecular weight PAS having a weight average molecular weight of 5,000 or less. For example, the properties such as mechanical properties are significantly inferior to those of the granular PAS. Has been conventionally recognized as being difficult and not worth industrial use. Therefore, the PAS mixture obtained by this method has usually been treated as industrial waste.

  As a result of detailed analysis of the PAS mixture other than the granular PAS, the present inventors include 10% by weight or more of the cyclic PAS (m = 4 to 20) represented by the formula (1). In particular, since these were obtained as a mixture of m = 4 to 20, it was found preferable as a raw material for obtaining the cyclic PAS compound of the present invention. This is significant from the viewpoint of recovering a compound having an extremely high industrial utility value from what was conventionally regarded as industrial waste by the method of the present invention.

  As a method for recovering PAS from the recovered slurry, for example, at least 50% by weight or more of an organic polar solvent is removed from the recovered slurry, a residue is obtained, water is added thereto, and then an acid is added as desired. A method in which at least the residual organic polar solvent and the alkali metal halide are removed and the PAS mixture is separated and recovered, or a method in which the PAS mixture is precipitated from the recovered slurry and PAS is recovered as a solid component, such as a recovered slurry. Examples thereof include a method of obtaining PAS as a solid component by a known solid-liquid separation method such as decantation, centrifugation, and filtration after precipitation of PAS by adding water.

(5) Preparation of cyclic PAS compound-containing solution In the present invention, a solution containing a cyclic PAS compound is prepared by bringing the PAS compound into contact with a solvent capable of dissolving the cyclic PAS compound (m = 4 to 20) described in formula (1). Prepare.

  The solvent used here is not particularly limited as long as it is a solvent capable of dissolving the cyclic PAS compound. However, a solvent in which the cyclic PAS compound dissolves in a dissolving environment but PAS is difficult to dissolve, and a solvent in which PAS does not dissolve is preferred. Is more preferable. The pressure of the reaction system when the PAS is brought into contact with the solvent is preferably normal pressure or slight pressure, and particularly preferably normal pressure. The reaction system of such pressure is advantageous in that the components of the reactor for constructing it are inexpensive. There is. From this point of view, it is desirable that the reaction system pressure avoid pressurizing conditions that require an expensive pressure vessel. As the solvent to be used, those which do not substantially cause undesired side reactions such as decomposition and crosslinking of PAS and cyclic PAS compounds are preferable, and as a preferable solvent when the operation of bringing the PAS mixture into contact with the solvent is performed, for example, under atmospheric pressure reflux conditions. Are, for example, hydrocarbon solvents such as benzene, toluene, xylene, halogen solvents such as chloroform, bromoform, methylene chloride, 1,2-dichloroethane, 1,1,1-trichloroethane, chlorobenzene, 2,6-dichlorotoluene, Ketone solvents such as acetone, diethyl ketone, methyl ethyl ketone, methyl isobutyl ketone, methyl butyl ketone, acetophenone, ether solvents such as diethyl ether, tetrahydrofuran, diisopropyl ether, N, N-dimethylformamide, N, N-dimethyl Examples include polar solvents such as cetamide, dimethyl sulfoxide, trimethyl phosphoric acid, N, N-dimethylimidazolidinone, among which benzene, toluene, xylene, chloroform, bromoform, methylene chloride, 1,2-dichloroethane, 1,1, 1-trichloroethane, chlorobenzene, 2,6-dichlorotoluene, acetone, diethyl ketone, methyl ethyl ketone, methyl isobutyl ketone, methyl butyl ketone, diethyl ether, tetrahydrofuran, diisopropyl ether, N, N-dimethylformamide, N, N-dimethylacetamide, Dimethyl sulfoxide, trimethyl phosphate and N, N-dimethylimidazolidinone are preferable, and toluene, xylene, chloroform, methylene chloride and tetrahydrofuran are more preferable. It can be shown.

  There is no particular limitation on the atmosphere in which the PAS is brought into contact with the solvent. However, when the PAS or the solvent is oxidized and deteriorated depending on conditions such as the temperature and time at which the PAS is brought into contact with the solvent, it is desirable to perform in a non-oxidizing atmosphere. . Note that the non-oxidizing atmosphere is an atmosphere having a gas phase oxygen concentration of 5% by volume or less, preferably 2% by volume or less, more preferably an oxygen-free atmosphere such as nitrogen, helium, argon, or the like. Among these, a nitrogen atmosphere is particularly preferable from the viewpoints of economy and ease of handling.

  The temperature at which the PAS mixture is brought into contact with the solvent is not particularly limited, but generally, the higher the temperature, the more the dissolution of the cyclic PAS compound in the solvent tends to be promoted. As described above, since the contact of the PAS mixture with the solvent is preferably performed under atmospheric pressure, the upper limit temperature is preferably set to the reflux condition temperature under atmospheric pressure of the solvent used. For example, 20 to 150 ° C. can be exemplified as a specific temperature range.

  The time for bringing the PAS mixture into contact with the solvent varies depending on the type of solvent used, the temperature, etc., but cannot be uniquely limited. For example, 1 minute to 50 hours can be exemplified, and if it is too short, the cyclic PAS is not sufficiently dissolved in the solvent. If it is too long, dissolution in the solvent reaches a saturated state, and no further effect can be obtained.

  The method of bringing PAS into contact with a solvent is not particularly limited as long as a known general method is used. For example, a method of collecting a PAS mixture and a solvent, stirring the solution as necessary, and then collecting a solution portion, various filters Any method can be used, such as a method in which the PAS mixture is showered with a solvent and at the same time the cyclic PAS is dissolved in the solvent, or a method based on the Soxhlet extraction principle. Although there is no restriction | limiting in particular in the usage-amount of the solvent at the time of making PAS and a solvent contact, For example, the range of 0.5-100 can be illustrated by the bath ratio with respect to PAS weight. When the bath ratio is too small, not only is the mixing of the PAS mixture and the solvent difficult, but the cyclic PAS compound tends to be insufficiently dissolved in the solvent. A larger bath ratio is generally advantageous for dissolving a cyclic PAS compound in a solvent, but if it is too large, no further effect can be expected, and conversely, there may be an economic disadvantage due to an increase in the amount of solvent used. . When the contact between the PAS and the solvent is repeated, a sufficient effect can often be obtained even with a small bath ratio. In addition, the Soxhlet extraction method, in principle, provides an effect similar to the case where the contact between the PAS and the solvent is repeated, and in this case, a sufficient effect can often be obtained with a small bath ratio.

  After the PAS is brought into contact with the solvent, when the solution in which the cyclic PAS compound is dissolved is obtained in the form of a solid-liquid slurry containing the remaining solid PAS, the solution portion is recovered using a known solid-liquid separation method. . Examples of the solid-liquid separation method include separation by filtration, centrifugation, and decantation. For the solution thus separated, the solvent described later is removed. On the other hand, for the remaining solid component, when the cyclic PAS compound still remains, specifically, when 0.05% by weight or more of the cyclic PAS compound remains on a weight basis, A cyclic PAS compound can be obtained with higher yield by repeatedly performing contact and solution recovery. Further, when the cyclic PAS compound hardly remains, specifically, when the cyclic PAS compound remains less than 0.05% by weight, the residual solid PAS is removed by removing the residual solvent. Can be suitably recycled as high-purity PAS.

(6) Removal of solvent from cyclic PAS compound solution In the present invention, the solvent is removed from the solution containing the cyclic PAS compound (m = 4 to 20) represented by the formula (1) obtained as described above. To obtain a cyclic PAS compound. The removal of the solvent can be exemplified by, for example, a method of heating and treating at normal pressure or less, and removal of the solvent using a membrane. However, from the viewpoint of obtaining a cyclic PAS compound with higher yield and efficiency. A method of removing the solvent by heating at a pressure lower than the pressure is preferred. The solution containing the cyclic PAS compound obtained as described above may contain a solid depending on the temperature. In this case, the solid belongs to the cyclic PAS compound. It is desirable to recover together with the soluble component, whereby a cyclic PAS compound can be obtained with good yield.
In removing the solvent, it is desirable to remove at least 50% by weight, preferably 70% by weight or more, more preferably 90% by weight or more, and still more preferably 95% by weight or more. Although the temperature at which the solvent is removed by heating depends on the characteristics of the solvent used, it cannot be limited uniquely. However, the temperature can usually be selected from 20 to 150 ° C, preferably from 40 to 120 ° C. In addition, the pressure for removing the solvent is preferably normal pressure or lower, which makes it possible to remove the solvent at a lower temperature.

(7) Other post-treatments Although the cyclic PAS compound obtained by the method described in (4) to (6) has a sufficiently high purity, it can be suitably used as a cyclic PAS compound of m = 4 to 20, Furthermore, it is possible to obtain a cyclic PAS compound with higher purity and a cyclic PAS simple substance with m = 6 by additionally performing post-treatment described below.

  The cyclic PAS compound obtained by the operations (4) to (6) may contain an impurity component contained in PAS depending on the characteristics of the solvent used. Impurities are dissolved in cyclic PAS compounds containing such small amounts of impurities, but cyclic PAS compounds are not dissolved or contacted with a second solvent in which cyclic PAS compounds are difficult to dissolve, thereby selectively removing impurity components. Often it is possible to do.

  The pressure of the reaction system when the cyclic PAS compound is contacted with the second solvent is preferably normal pressure or slight pressure, and particularly preferably normal pressure, and the reaction system having such pressure is inexpensive to construct the members. There is an advantage. From this point of view, it is desirable that the reaction system pressure avoid pressurizing conditions that require an expensive pressure vessel. As the preferred solvent as the second solvent, those which do not substantially cause undesirable side reactions such as decomposition and crosslinking of the target cyclic PAS compound are preferable. For example, methanol, ethanol, propanol, butanol, pentanol, ethylene glycol, Alcohol / phenolic solvents such as propylene glycol, phenol, cresol, polyethylene glycol, hydrocarbon solvents such as pentane, hexane, heptane, octane, cyclohexane, cyclopentane, acetone, methyl ethyl ketone, diethyl ketone, methyl isobutyl ketone, methyl butyl ketone, Ketone solvents such as acetophenone, methyl acetate, ethyl acetate, pentyl acetate, octyl acetate, methyl butyrate, ethyl butyrate, pentyl butyrate, methyl salicylate, ethyl formate, etc. Examples of rubonic acid solvents include methanol, ethanol, propanol, butanol, pentanol, ethylene glycol, propylene glycol, pentane, hexane, heptane, octane, cyclohexane, and cyclopentane, and methanol, ethanol, propanol, and ethylene. Glycol, pentane, hexane, heptane, octane, cyclohexane, acetone and ethyl acetate are particularly preferred. These solvents can be used as one kind or a mixture of two or more kinds.

  There is no particular limitation on the temperature at which the cyclic PAS compound is brought into contact with the second solvent, but the upper limit temperature is preferably the reflux condition temperature under normal pressure of the second solvent to be used. When using, 20-100 degreeC can be illustrated as a preferable temperature range, for example, More preferably, 25-80 degreeC can be illustrated.

The time for contacting the cyclic PAS compound with the second solvent cannot be uniquely limited because it varies depending on the type of solvent used, the temperature, etc., but for example, 1 minute to 50 hours can be exemplified, and if it is too short, impurities in the cyclic PAS compound In this case, the dissolution of the impurities in the second solvent reaches a saturated state, and no further effect can be obtained.
As a method for bringing the cyclic PAS compound into contact with the second solvent, a method in which the solid cyclic PAS compound and the second solvent are stirred and mixed as necessary, and the second solvent is added to the cyclic PAS compound solid on various filters. A method of dissolving impurities in a second solvent at the same time as showering, a method using Soxhlet extraction of a solid cyclic PAS compound using a second solvent, a cyclic PAS compound slurry containing a solution-like cyclic PAS compound or solvent For example, a method in which the cyclic PAS compound is precipitated in the presence of the second solvent by bringing the compound into contact with the second solvent can be used. In particular, the method of bringing a cyclic PAS compound slurry containing a solvent into contact with the second solvent is an effective method because the cyclic PAS compound obtained after the operation has a high purity.

  After contacting the cyclic PAS compound with the second solvent, a slurry in which the cyclic PAS compound is precipitated in the second solvent is obtained, so that the solid cyclic PAS compound is recovered using a known solid-liquid separation method. To do. Examples of the solid-liquid separation method include separation by filtration, centrifugation, and decantation. If impurities still remain in the cyclic PAS compound obtained after solid-liquid separation, it is also possible to contact the cyclic PAS compound and the second solvent again to further remove the impurities.

(8) Characteristics of the cyclic PAS compound of the present invention In the cyclic PAS compound thus obtained, m in the formula (1) is 4 to 20, and m = 4 to 20 represented by the formula (1) is different. A cyclic PAS compound having m is preferable, and a cyclic PAS compound having a cyclic PAS content of m = 6 in the cyclic PAS compound is preferably less than 50% by weight.

  In addition, m of the cyclic PAS compound of the present invention is m = 4 to 20 as described above, and m may be a mixture of 4 to 20, but as a cyclic PAS compound, m = 4 to 12 is studied by the authors. In the case where m is in this range, it has been found that the degree of polymerization by cyclic heating of the cyclic PAS compound proceeds promptly as described later.

  In addition, although the possibility that the cyclic PPS compound whose m is 12 or more exists is high, it is difficult to qualitatively and quantitatively with the current analysis technique. This is because, as will be described later, it is difficult to distinguish between a linear PAS oligomer contained in a cyclic PAS compound and a cyclic PAS having m = 13 or more with the latest analysis technique at present. However, when a cyclic PAS compound of m = 4 to 20 is melted and heated, the degree of polymerization of the cyclic PAS compound rapidly proceeds, the amount of volatile gas components in the resulting PAS resin is reduced, and the cyclic PAS compound contains When the content of m = 6 cyclic PAS alone is less than 50% by weight, these effects are further enhanced, so that a cyclic PAS compound having m of 13 or more is included within the range not impairing the effects of the present invention. It may be.

  Further, the cyclic PAS compound obtained by the method described in (4) to (7) is sufficiently high in purity, but depending on conditions, a linear PAS oligomer may be contained as an impurity. Further, as described above, it is difficult to distinguish this linear PAS oligomer from a cyclic PAS compound having m = 13 or more with the latest analysis technique at present. The weight average molecular weight (Mw) of the oligomer component presumed to be a linear PAS oligomer varies depending on the production method of the PAS used as the raw material of the cyclic PAS compound described in (4), but is usually 5000 or less. Yes, in some cases it is 2000 or less.

  The linear PAS oligomer remaining as an impurity in the cyclic PAS compound has poor thermal stability and increases the amount of volatile gas components as compared with the cyclic PAS compound. If these are contained in a large amount as impurities, there arises a problem that the conversion of the cyclic PAS compound to PAS by melting and heating becomes insufficient.

  Therefore, the amount of the linear PAS oligomer in the cyclic PAS compound obtained by the method described in (4) to (7) is preferably less than 50% by weight and less than 40% by weight with respect to the total cyclic PAS compound. More preferably, it is less than 30% by weight.

  The amount of linear PAS oligomer in the cyclic PAS compound at this time can be quantified by MALDI-TOF-MS as the total amount with the cyclic PAS compound of m = 13 or more according to the present analysis technique. It is.

  Further, as described in JP-A-10-77408, a cyclic PAS compound is subjected to Soxhlet extraction from a crosslinked type PAS, the extract is cooled, and the precipitated white solid is converted into m = No. 6 cyclic PAS is obtained with high purity (cyclohexa (p-phenylene sulfide). Although the recovery amount is small compared with the cross-linked PAS, the same can be obtained from linear PAS. In the same way, it is possible to obtain a simple cyclic PAS of m = 6 with high purity by carrying out the extraction operation and “recrystallization”.

  The simple cyclic PAS of m = 6 has an extremely stable needle-like crystal structure and is easy to crystallize. Therefore, while it is a ring suitable for the method of “recrystallization”, its stable needle-like crystal structure is Reflecting this, the melting point becomes as high as 348 ° C., so it is necessary to increase the melting heating temperature for increasing the degree of polymerization.

  In the case of only m = 6 cyclic PAS alone, the method is such that the cyclic PAS compound is dissolved and supplied in a solvent, and the crystallized cyclic PAS is melted at a melting point or higher and then rapidly cooled to suppress crystallization. A method of supplying an amorphous powder, or a method in which the premelter is set to a melting point of the cyclic PAS or higher and the cyclic PAS alone is melted in the premelter and supplied as a melt. it can. In the case of using cyclic PAS alone, it is necessary to increase the melting heating temperature for increasing the degree of polymerization, or as described above, once the cyclic PAS is melted once, crystallization is suppressed to be amorphous. From the aspect of productivity and melt processability for increasing the degree of polymerization of cyclic PAS, it is necessary to melt only cyclic PAS alone in the premelter and supply it as a melt. The content of m = 6 cyclic PAS alone in the PAS compound is preferably less than 50% by weight, more preferably less than 30% by weight, and still more preferably less than 10% by weight.

  The reason for this is currently interpreted as follows. That is, when the content of the cyclic PAS simple substance with m = 6 is reduced, there is an effect that the cyclic PAS simple substance does not act as a crystal nucleus. As a result, the cyclic PAS compound composed of a mixture with m = 4 or more is obtained. It is considered that the crystallization is suppressed and the melting point of the cyclic PAS compound is lowered, so that the cyclic PAS compound is easily melted, and as a result, the degree of polymerization can be easily increased by melting and heating.

  In addition, since cyclic monomers other than m = 6 are difficult to crystallize compared to m = 6, it has been difficult to obtain a monomer by a method called “recrystallization” (isolated by a method called recrystallization). Only the cyclic PAS simple substance of m = 6 is possible), the authors separated and recovered these monomers by a collection liquid chromatogram, and the cyclic PAS simple substance of m = 4 (cyclotetra (p-phenylene sulfide), melting point 296 )), M = 5 cyclopenta (p-phenylene sulfide) (melting point 257 ° C.), m = 7 cyclohepta (p-phenylene sulfide) (melting point 328 ° C.), m = 8 cycloocta (p-phenylene sulfide) ( It was confirmed that the melting point was 305 ° C.

  That is, according to the methods described in (4) to (7), the obtained cyclic PAS compound is a mixture having different m, and a cyclic PAS simple substance having m = 6 is less than 50% by weight. . Depending on the conditions, it is possible to obtain a cyclic PAS content of m = 6 less than 30% by weight, or even less than 10% by weight. The obtained cyclic PAS compound has a characteristic that the melting temperature is lower than that of a single cyclic PAS composed of m. This is because, for example, a cyclic PAS compound can be obtained by a simple method and a high molecular weight polymer at a low melting heating temperature. It is possible to convert to

(9) Conversion of cyclic PAS compound to high polymerization degree The PAS of the present invention described above is preferably produced by a method in which the cyclic PAS compound is melt-heated and converted to a high polymerization degree. The melting heating temperature is preferably a temperature at which the cyclic PAS compound melts and is not particularly limited as long as it is such temperature conditions. If the heating temperature is lower than the melting temperature of the cyclic PAS compound, a long time tends to be required to increase the degree of polymerization of PAS. The temperature at which the cyclic PAS compound melts varies depending on the composition and purity of m present in the cyclic PAS compound as described above. For example, by analyzing the cyclic PAS compound with a differential scanning calorimeter, By grasping, it is possible to melt and heat above its melting temperature. However, if the temperature is too high, undesirable side reactions such as crosslinking reaction and decomposition reaction between PAS molecules produced by heating and between PAS and cyclic PAS compounds tend to occur, and the resulting PAS Therefore, it is desirable to avoid a temperature at which such an undesirable side reaction is remarkably generated. 180-400 degreeC can be illustrated as melt-heating temperature, Preferably it is 200-380 degreeC, More preferably, it is 250-360 degreeC.

  The time for performing the melting and heating cannot be uniformly defined because it varies depending on various properties such as the composition of m in the cyclic PAS compound to be used, the purity of the cyclic PAS compound, and the conditions such as the heating and melting temperature. It is preferable to set so that undesirable side reactions do not occur as much as possible. Examples of the heating and melting time include 0.05 to 100 hours, preferably 0.1 to 20 hours, and more preferably 0.1 to 10 hours. If it is less than 0.05 hours, the conversion of the cyclic PAS compound to PAS tends to be insufficient, and if it exceeds 100 hours, the possibility of adverse effects on the properties of the resulting PAS due to undesirable side reactions tends to become obvious. Not only that, but there may be economic disadvantages.

  Conversion of the cyclic PAS compound to a high degree of polymerization by melting and heating is usually performed in the absence of a solvent, but can also be performed in the presence of a solvent. The solvent is not particularly limited as long as it does not substantially cause an undesirable side reaction such as inhibition of conversion of the cyclic PAS compound to a high degree of polymerization by heating and decomposition or crosslinking of the produced PAS. Nitrogen-containing polar solvents such as methyl-2-pyrrolidone, dimethylformamide, dimethylacetamide, sulfoxide / sulfone solvents such as dimethyl sulfoxide, dimethyl sulfone, ketone solvents such as acetone, methyl ethyl ketone, diethyl ketone, acetophenone, dimethyl ether, dipropyl ether , Ether solvents such as tetrahydrofuran, halogen solvents such as chloroform, methylene chloride, trichloroethylene, ethylene chloride, dichloroethane, tetrachloroethane, chlorobenzene, methanol, ethanol, propano Le, butanol, pentanol, ethylene glycol, propylene glycol, phenol, cresol, alcohol phenol based solvents such as polyethylene glycol, benzene, toluene, and aromatic hydrocarbon solvents such as xylene. It is also possible to use an inorganic compound such as carbon dioxide, nitrogen, or water as a solvent in a supercritical fluid state. These solvents can be used as one kind or a mixture of two or more kinds.

  The conversion of the cyclic PAS compound into a high degree of polymerization by heating may be performed in a mold for producing a molded product, as well as by a method using a normal polymerization reaction apparatus, an extruder, Any apparatus equipped with a heating mechanism, such as a melt kneader, can be used without particular limitation, and known methods such as a batch method and a continuous method can be employed. Moreover, when superposing | polymerizing, you may superpose | polymerize by putting an inorganic filler, By doing so, the highly filled composition with the favorable dispersibility of a filler is obtained.

  The atmosphere during the conversion of the cyclic PAS compound to a high degree of polymerization by heating is preferably a non-oxidizing atmosphere, and is also preferably performed under reduced pressure. Moreover, when it carries out under pressure reduction conditions, it is preferable to make it the pressure reduction conditions after making the atmosphere in a reaction system once non-oxidizing atmosphere. This tends to suppress the occurrence of undesired side reactions such as a crosslinking reaction and a decomposition reaction during conversion to a degree of polymerization due to overheating. The non-oxidizing atmosphere is an atmosphere in which the oxygen concentration in the gas phase in contact with the cyclic PAS compound is 5% by volume or less, preferably 2% by volume or less, more preferably substantially free of oxygen, that is, nitrogen, helium, argon, etc. In particular, a nitrogen atmosphere is preferable from the viewpoint of economy and ease of handling. The reduced pressure condition means that the reaction system is lower than atmospheric pressure, and the upper limit is preferably 50 kPa or less, more preferably 20 kPa or less, and even more preferably 10 kPa or less. An example of the lower limit is 0.1 kPa or more, and 0.2 kPa or more is more preferable. When the decompression condition exceeds the preferable upper limit, an undesirable side reaction such as a crosslinking reaction tends to occur. On the other hand, when it is less than the preferable lower limit, the cyclic PAS compound having a low molecular weight contained in the cyclic PAS compound volatilizes depending on the reaction temperature. It tends to be easier.

(10) Inorganic filler (b) Inorganic filler used in the present invention includes fibrous or non-fibrous (plate-like, scale-like, granular, indefinite shape, crushed product, etc.) fillers, specifically For example, glass fiber, PAN-type or pitch-type carbon fiber, stainless steel fiber, metal fiber such as aluminum fiber or brass fiber, gypsum fiber, ceramic fiber, asbestos fiber, zirconia fiber, alumina fiber, silica fiber, oxidation as fibrous filler Examples include titanium fiber, silicon carbide fiber, rock wool, potassium titanate whisker, barium titanate whisker, barium strontium titanate whisker, aluminum borate whisker, silicon nitride whisker, and zinc oxide whisker. Also commonly used for resin reinforcement If it is, there will be no limitation in particular, For example, it can select and use from a long fiber type, a short fiber type chopped strand, a milled fiber, etc. The filler may be coated or focused with a thermoplastic resin such as an ethylene / vinyl acetate copolymer, a thermosetting resin such as an epoxy resin, a silane compound, a titanate compound, or an aluminum compound.

  Zinc oxide whiskers, mica, talc, kaolin, silica, calcium carbonate, glass beads, glass flakes, glass microballoons, clay, molybdenum disulfide, wollastonite, calcium polyphosphate, graphite, metal powder, metal flakes as non-fibrous filler Examples thereof include metal ribbons, metal oxides (alumina, zinc oxide, titanium oxide, etc.), carbon powder, graphite, carbon flakes, scale-like carbon, and nanocarbon tubes. Moreover, silver, nickel, copper, zinc, aluminum, stainless steel, iron, brass, chromium, tin etc. can be illustrated as a specific example of the metal seed | species of metal powder, metal flakes, and a metal ribbon.

  Also possible for non-fibrous fillers are surface treatment agents such as thermoplastic resins such as ethylene / vinyl acetate copolymers, thermosetting resins such as epoxy resins, silane compounds, titanate compounds, and aluminum compounds. It may be processed.

  In addition, for example, high heat conductive fillers are preferably used for applications requiring high heat dissipation, and specifically, metal powder, metal flakes, metal ribbons, metal fibers, metal oxides (alumina, zinc oxide, etc.) , Carbon powder, graphite, PAN-based or pitch-based carbon fiber, carbon flake, scaly carbon, carbon nanotube, boron nitride, aluminum nitride, silicon nitride, silicon carbide and the like.

  Here, specific examples of the metal species of the metal powder, metal flake, and metal ribbon include silver, nickel, copper, zinc, aluminum, stainless steel, iron, brass, chromium, and tin.

Specific examples of the metal oxide include SnO ₂ (antimony dope), In ₂ O ₃ (antimony dope) and ZnO (aluminum dope), and these include titanate, aluminum and silane. The surface treatment may be performed with the surface treatment agent.

  The carbon powder is classified into acetylene black, gas black, oil black, naphthalene black, thermal black, furnace black, lamp black, channel black, roll black, disc black, and the like based on the raw materials and the production method. The carbon powder that can be used in the present invention is not particularly limited in terms of its raw material and production method, and among them, acetylene black and furnace black are particularly preferably used. Further, as the carbon powder, various carbon powders having different characteristics such as particle diameter, surface area, DBP (dibutyl phthalate) oil absorption and ash content are manufactured and commercially available. The carbon powder that can be used in the present invention is not particularly limited with respect to these properties, but from the viewpoint of the balance between strength and electrical conductivity, the average primary particle size is 500 nm or less, particularly 5 to 100 nm, It is preferable that it exists in the range of 10-70 nm. The surface area (BET method) is preferably in the range of 10 m 2 / g or more, more preferably 30 m 2 / g or more. Furthermore, the DBP oil supply amount is preferably 50 ml / 100 g or more, particularly preferably 100 ml / 100 g or more. Furthermore, it is preferable that the ash content is 0.5% or less, particularly 0.3% or less.

  Such carbon powder may be surface-treated with a surface treatment agent such as titanate, aluminum, and silane. Moreover, it is also possible to use what was granulated in order to improve melt-kneading workability | operativity with resin.

  In the present invention, it is preferable to use two or more fibrous and non-fibrous materials in combination for high balance between strength and fluidity. Specifically, (a) one or more combinations selected from graphite and carbon fiber, glass fiber, potassium titanate whisker, barium titanate whisker, aluminum borate whisker, silicon nitride whisker and zinc oxide whisker, or (b) One or more combinations selected from alumina and carbon fiber, glass fiber, potassium titanate whisker, barium titanate whisker, aluminum borate whisker and silicon nitride whisker, or (c) graphite and carbon fiber, zinc oxide whisker and / or One or more combinations selected from non-fibrous fillers can be mentioned.

  In the present invention, the ratio of (a) polyarylene sulfide and (b) filler exhibits the characteristics of the filler used and is blended from the viewpoint of balance with melt processability and (a) polyarylene sulfide and (b (A) 5-50% by volume of polyarylene sulfide, and (b) 95-50% by volume of inorganic filler, preferably (a) 8-45% by volume of polyarylene sulfide, with respect to 100% by volume of the total amount of inorganic filler. (B) Inorganic filler 92-55 volume%, More preferably, (a) Polyarylene sulfide 10-40 volume%, (b) Inorganic filler 90-60 volume is preferable.

  Further, when using a fibrous filler and a non-fibrous filler in combination, it is preferable that the non-fibrous filler is more than the fibrous filler in terms of the balance of molding fluidity and mechanical strength, specifically, The amount is preferably 2% by weight or more, more preferably 5% by weight or more.

  In order to improve the fluidity and mechanical strength by reducing the porosity between fillers in the filler (b) inorganic filler used as a feature of the present invention, the particle size is distributed over a wide range. It is preferable that the ratio (D90 / D10) of the 90% cumulative particle size (D90) and the 10% cumulative particle size (D10) obtained from the cumulative particle size distribution curve measured by the laser diffraction method is 10 or more. Is preferable, more preferably 11 or more, and still more preferably 13 or more. The upper limit is not particularly limited, but is 1000 considering productivity and the like.

  Further, in order to maximize the individual filler characteristics, the average particle diameter (D50) of the inorganic filler (b) obtained by the laser beam diffraction method is preferably 1 to 100 μm, more preferably 3 to 80 μm. 4 to 50 μm is preferable.

  The measurement by the laser beam diffraction method is a laser diffraction particle size distribution measuring device (for example, a laser diffraction particle size distribution measuring device SALD-3100 manufactured by Shimadzu Corporation) at a concentration of 100 ppm using a dispersible liquid such as water or a solvent as a dispersion medium. Use to measure.

  In addition, since the present invention is highly filled with fillers, lubricity between inorganic fillers is important, and as a particle size distribution therefor, it is ideal to have a uniform distribution over a wide particle size range, a so-called trapezoidal distribution. However, it is also preferable to have a bimodal particle size distribution such as bimodal and trimodal having two mountain distributions. Furthermore, in the case of multimodality, it is preferable that the peak on the coarse particle side is higher in terms of strength improvement.

  In order to make the filler used in the present invention have such a particle size distribution as described above, for example, two or more fillers having different average particle sizes or particle size distributions are used in combination, or those obtained by fractionation by particle size by sieving or the like are desired. The method of mixing so that it may become particle size distribution of this, the method of using together 2 or more types of fillers from which particle size distribution differs are employable.

  The particle size distribution is indicated by a curve in which the amount of particles (%) in each particle size interval measured by a laser diffraction particle size distribution measuring device is plotted. The cumulative particle size distribution curve is equal to or less than the particle size. It is a curve obtained by accumulating the amount of particles (%), and represents the percentage of the total amount of particles having a specific particle diameter or less.

  In addition, the present invention includes the following (c) fatty acid metal salt, ester compound, amide group-containing compound, epoxy compound, and phosphate ester from the viewpoint of imparting bondability at the filler interface and imparting flow improvement during processing. It is preferable to add at least one selected from Such additives include calcium stearate, magnesium stearate, zinc stearate, barium stearate, aluminum stearate, calcium montanate, magnesium montanate, zinc montanate, barium montanate, aluminum montanate and other fatty acid metals Salts, and derivatives thereof, stearates such as methyl stearate and stearate stearate, myristic esters such as myristyl myristate, montanate esters, methacrylate esters such as behenyl methacrylate, pentaerythritol monostearate, 2 -Cetyl ethylhexanoate, methyl palm fatty acid, methyl laurate, isopropyl myristate, octyldodecyl myristate, butyl stearate, stearic acid -Ethylhexyl, isotridecyl stearate, methyl caprate, methyl myristate, methyl oleate, octyl oleate, lauryl oleate, oleyl oleate, 2-ethylhexyl oleate, decyl oleate, octidodecyl oleate, isobutyl oleate, etc. Monohydric alcohol esters of fatty acids and their derivatives, distearyl phthalate, distearyl trimelliate, dimethyl adipate, dioleyl adipate, adipate, ditridecyl phthalate, diisobutyl adipate, diisodecyl adipate, dibutyl glycol adipate , 2-ethylhexyl phthalate, diisononyl phthalate, didecyl phthalate, tri-2-ethylhexyl trimellitic acid, triisodecyl trimellitic acid, etc. Fatty acid esters of basic acids, stearic acid monoglyceride, palmitic acid / stearic acid monoglyceride, stearic acid mono / diglyceride, stearic acid / oleic acid / mono / diglyceride, fatty acid esters of glycerin and their derivatives, sorbitan tristearate Rate, sorbitan monostearate, sorbitan monostearate, sorbitan distearate, sorbitan monopalmitate, sorbitan monostearate, polyethylene glycol monostearate, polyethylene glycol distearate, polypropylene glycol monostearate, pentaerythritol monostearate , Sorbitan monolaurate, sorbitan trioleate, sorbitan monooleate, sorbitan Sekizolate, sorbitan monolaurate, polyoxymethylene sorbitan monolaurate, polyoxymethylene sorbitan monopalinate, polyoxymethylene sorbitan monostearate, polyoxymethylene sorbitan monooleate, polyoxymethylene sorbitan tetraoleate, polyethylene glycol, polyethylene glycol Fatty acid esters of polyhydric alcohols such as monolaurate, polyethylene glycol monooleate, polyoxyethylene bisphenol A laurate, pentaerythritol, pentaerythritol monooleate, and derivatives thereof, ethylene bisstearylamide, ethylenebisoleylamide, stearyl Amide group-containing compounds such as erucamide, novolac phenyl type, bisphenol Le-type monofunctional and polyfunctional epoxy compounds, aromatic phosphoric acid esters such as triphenyl phosphate, and phosphate esters such as aromatic condensed phosphate.

  Especially about phosphate ester, it is chosen from the monoester, diester, triester, and tetraester of phosphoric acid, Preferably, what is represented by following formula (1) is mentioned.

  First, the structure of the phosphate ester represented by the formula (1) will be described. In the formula of the formula (1), n is an integer of 0 or more, preferably 0 to 10, particularly preferably 0 to 5. The upper limit is preferably 40 or less from the viewpoint of dispersibility.

  K and m are each an integer of 0 or more and 2 or less, and k + m is an integer of 0 or more and 2 or less, preferably k or m is an integer of 0 or more and 1 or less, particularly preferably k or m. Is 1 respectively.

In the formula (1), R ^{3 to} R ¹⁰ represent the same or different hydrogen or an alkyl group having 1 to 5 carbon atoms. Specific examples of the alkyl group having 1 to 5 carbon atoms include methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, sec-butyl group, tert-butyl group, tert-pentyl group, Among them, hydrogen, methyl group, and ethyl group are preferable, and hydrogen is particularly preferable.

Ar ¹ , Ar ² , Ar ³ and Ar ⁴ represent the same or different aromatic groups or aromatic groups substituted with an organic residue containing no halogen. Examples of the aromatic group include aromatic groups having a benzene skeleton, a naphthalene skeleton, an indene skeleton, and an anthracene skeleton, and among them, those having a benzene skeleton or a naphthalene skeleton are preferable. These may be substituted with a halogen-free organic residue (preferably an organic residue having 1 to 8 carbon atoms), and the number of substituents is not particularly limited, but may be 1 to 3. preferable. Specific examples include phenyl groups, tolyl groups, xylyl groups, cumenyl groups, mesityl groups, naphthyl groups, indenyl groups, anthryl groups and the like, but phenyl groups, tolyl groups, xylyl groups, cumenyl groups, A naphthyl group is preferable, and a phenyl group, a tolyl group, and a xylyl group are particularly preferable.

Y represents a direct bond, O, S, SO ₂ , C (CH ₃ ) ₂ , CH ₂ , CHPh, and Ph represents a phenyl group.

  Specific examples of such phosphate esters are selected from Daihachi Chemical Co., Ltd. PX-200, PX-201, PX-130, CR-733S, TPP, CR-741, CR-747, TCP, TXP, CDP. One or more selected from the group consisting of PX-200, TPP, CR-733S, CR-741, and CR-747, particularly preferably PX-200. , CR-733S and CR-741 can be used, but PX-200 is most preferable.

  In this invention, any 1 type of phosphate ester, or a mixture of 2 or more types may be sufficient. The addition amount of such additives is 0.1 to 10 parts by weight, preferably 0.1 to 8 parts by weight, based on 100 parts by weight of the total amount of (a) thermoplastic resin and (b) inorganic filler. A range of 0.3 to 6 parts by weight is preferably selected.

  (C) When the addition amount of the fatty acid metal salt, ester compound, amide group-containing compound, epoxy compound, and phosphate ester is within the above range, the surface of the molded product obtained is too much in the range of the present invention. The mechanical properties are not deteriorated due to the peeling of the interface between (a) polyarylene sulfide and (b) filler.

  In the highly filled resin composition of the present invention, other components such as antioxidants and heat stabilizers (hindered phenol-based, hydroquinone-based, phosphite-based, and substituted products thereof are used as long as the effects of the present invention are not impaired. Etc.), weathering agents (resorcinol, salicylate, benzotriazole, benzophenone, hindered amine, etc.), mold release agents and lubricants (montanic acid and its metal salts, esters, half esters, stearyl alcohol, stearamide, various Bisamide, bisurea, polyethylene wax, etc.), pigment (cadmium sulfide, phthalocyanine, carbon black for coloring, etc.), dye (nigrosine, etc.), crystal nucleating agent (talc, silica, kaolin, clay, etc.), plasticizer (p-oxy) Octyl benzoate, N-butylbenzenesulfone Antistatic agents (alkyl sulfate type anionic antistatic agents, quaternary ammonium salt type cationic antistatic agents, nonionic antistatic agents such as polyoxyethylene sorbitan monostearate, betaine amphoteric antistatic agents) Agent), flame retardant (eg, red phosphorus, phosphate ester, melamine cyanurate, magnesium hydroxide, aluminum hydroxide, hydroxide, ammonium polyphosphate, brominated polystyrene, brominated polyphenylene ether, brominated polycarbonate, bromine Epoxy resins or combinations of these brominated flame retardants and antimony trioxide), and other polymers can be added.

  The highly filled resin composition of the present invention is usually produced by a known method. For example, (a) component, (b) component, (c) component and other necessary additives are prepared by pre-mixing or supplying them to an extruder or the like without being premixed and kneaded sufficiently. . In addition, when (b) an inorganic filler is added, in order to suppress breakage of the fiber of the fibrous filler, preferably, the component (a) and other necessary additives are introduced from the extruder, and (b) And (c) It adjusts by supplying a component to an extruder using a side feeder.

  When producing a resin composition, for example, melt-kneading at 180 to 350 ° C. using a single-screw extruder, twin-screw, three-screw extruder and kneader-type kneader equipped with a “unimelt” (R) type screw. To obtain a composition.

  When a large amount of filler is added, for example, as a method for obtaining a highly filled resin composition in which the filler is added in an amount exceeding 150 parts by weight relative to 100 parts by weight of the total amount of (a) and (b), For example, as disclosed in JP-A-8-1663, a method of extruding the head portion of the extruder and extruding, coarsely pulverizing and uniformly blending, or a method of compressing the raw material into a tablet can be mentioned. In particular, the method of tableting by compressing the raw material is preferable from the viewpoint of the quality stability of the obtained composition.

  In the present invention, a tablet refers to a granular material obtained by compacting a raw material containing a powdery raw material in a solid phase. Such a tablet can be obtained by compression molding a raw material containing a powdery raw material in a solid phase. Can do. In the above, the solid phase state means that the thermoplastic resin component contained in the raw material is not melted. For the compression molding, it is preferable to use a molding machine having a compression roll such as a tableting machine (rotary, single-shot, double, triple) or briquette machine.

As a specific method for tableting, for example, a thermoplastic resin powder and an inorganic filler are uniformly blended in a solid phase using a Banbury mixer, kneader, roll, uniaxial or biaxial extruder, and a tableting machine. Or it can obtain by making into a tablet (tablet) with the molding machine which has a compression roll. Also, the thermoplastic resin raw material and inorganic filler are dry blended in advance using a Banbury mixer, kneader, or roll, or melt blended once using a single or twin screw extruder, etc., and cooled. After being pulverized into a powder form, it can be formed into tablets (tablets) with a tableting machine or a molding machine having a compression roll. In this case, the thermoplastic resin component used for melt kneading is not particularly limited as long as it can be melt kneaded, either in powder form or pellet form, but it is a powder from the viewpoint of reducing variation in characteristics due to poor dispersion of inorganic filler. Preferably, it is in the form of a pulverized product. In addition, when the composition previously melt-kneaded using a single-screw or twin-screw extruder is powdered, if the amount of inorganic filler used is large, the fluidity deteriorates, so the pellet cannot be extruded from the die. However, in this case, as described in JP-A-8-1663, kneading and extrusion can be performed with the head portion of the extruder being opened. When the amount of the inorganic filler is large, a flaky composition may be obtained. In the present invention, if necessary, a pellet or flake composition obtained by melt-kneading in advance by these methods is cooled and pulverized to form a powder and then tableted. In addition, these methods can be combined into tablets. That is, a raw material selected from the following (A) to (D) can be adjusted to have a desired content and tableted.
(I) Thermoplastic resin (b) Inorganic filler (c) (c) One or more of fatty acid metal salts, ester compounds, amide group-containing compounds, epoxy compounds and phosphate esters (d) (a) to (a) (C) a composition obtained by melt-kneading two or more components selected from the components, the component (a) or the component (b) being essential, preferably a lump and a powder thereof. In view of the simplicity of the process, the mixture obtained by uniformly blending the raw materials (a) and (b) and the raw material (c) in a solid phase state as necessary is converted into a tablet by a tableting machine or a molding machine having a compression roll. A method of (tablet) is preferred.

  As the powders of the above components (a) and (c), those available in powder form such as polyarylene sulfide resin may be used. It can also be obtained by pulverizing the pellets at room temperature or by freeze pulverization. The freeze pulverization can be carried out by using a generally known hammer type pulverizer, cutter type pulverizer, or stone mill type pulverizer after being frozen with dry ice or liquid nitrogen. As the PAS powder used in the present invention, the maximum particle size when measured based on the laser diffraction particle size distribution measurement method from the viewpoint of making the composition uniform between the obtained tablets and improving the handleability of the obtained tablets. The number average particle diameter of the major axis is preferably 1000 μm or less, more preferably 800 μm or less, and even more preferably 500 μm or less. In order to obtain a powder having such a particle size, the powder obtained by pulverization or the like may be appropriately sieved using a sieve having a desired size.

  As the tablet shape of the highly filled resin composition of the present invention, when considering shape retention during transportation and easy crushability during molding, for example, cylindrical shape, elliptical columnar shape, truncated cone shape, spherical shape, elliptical spherical shape, Examples include egg shape, macek shape, disc shape, cubic shape, and prismatic shape. Among these, a cylindrical shape, an elliptical column shape, a truncated cone shape, a spherical shape, an elliptic spherical shape, an egg shape, and a Macek shape are preferable from the viewpoint of measurement stability during processing.

  Further, the tablet size of the tablet is preferably a bottom surface of 15 mm diameter or less × length of 20 mm or less, and the maximum value of the bottom surface diameter or length (height) is preferably less than 15 mm, and the minimum value is 1 mm or more. It is preferable that As for the method of defining the maximum diameter and the minimum diameter with respect to those having a bottom surface that is not circular, when the maximum diameter of the circumscribed circle is specified, the maximum diameter is preferably less than 15 mm, 1 mm or more, more preferably 12 mm. Hereinafter, it is good that it is 1.5 mm or more.

   In addition, in order to keep the shape stable during transportation, the compression fracture strength value (crush strength value) when pressure is applied perpendicularly to the side of the tableting surface of the tablet or the compression surface of the compression roll, Preferably it is 5-100N, More preferably, it is 15-80N. As a method for obtaining a preferable crushing strength value, for example, it is most dependent on the raw material composition. By adding the component (c) or in the tableting process, the raw material is supplied uniformly to the raw material supply pocket, compression High by reducing the number of rotations of the roll and extending the pressurization time of the material on the compression roll, using a feed screw in the hopper, and effective deaeration and pre-compression before roll compression with the screw. Tablet density is obtained and high crushing strength is obtained. The crushing strength value is measured by placing a tablet on a strain gauge such as a load cell, and lowering the indenter at a low speed (preferably 0.1 to 2.0 mm / sec), and straining the tablet at the time of compressive fracture. A method of measuring the pressure indicated by the gauge can be used.

  By using such a method, it becomes possible to obtain a resin material highly filled with a filler that could not be achieved conventionally.

  The molding method for molding the highly filled resin composition of the present invention is a three-dimensional molded product by a normal molding method (injection molding, press molding, injection press molding, etc.), gas injection molding, mucell molding method, etc. However, in view of productivity, injection molding or injection press molding is preferably employed. Moreover, when it has a welding part, it is possible to use general welding methods, such as a hot plate, a vibration, an ultrasonic wave, and a laser.

  The molded product thus obtained makes the best use of the characteristics of the inorganic filler to be used and is capable of being melt-molded. For example, high heat dissipation applications, metal replacement applications, ceramic replacement applications, electromagnetic wave shielding applications, high precision parts ( Low dimensional change), useful for high conductivity applications, specifically, various cases, gear cases, LED lamp related parts, connectors, relay cases, switches, variable capacitor cases, optical pickup lens holders, optical pickup slide bases, Various terminal boards, transformers, printed wiring boards, liquid crystal panel frames, power modules and their housings, plastic magnets, semiconductors, liquid crystal display parts, lamp covers for projectors, FDD carriages, FDD chassis, actuators, HDD parts such as chassis Computer related parts Electric / electronic parts represented by: audio equipment such as VTR parts, TV parts, irons, hair dryers, rice cooker parts, microwave oven parts, acoustic parts, audio laser discs (registered trademark), compact discs, digital video discs Houses represented by parts, lighting parts, refrigerator parts, air conditioner parts, office electrical product parts, office computer-related parts, telephone-related parts, facsimile-related parts, printer heads and parts related to printing heads and transfer rolls, Cleaning jigs, motor parts, microscopes, binoculars, cameras, optical instruments such as watches, precision machine related parts; alternator terminals, alternator connectors, IC regulators, light dimmer potentiometer bases, motor core sealing materials, SCHRATER components, power seat gear housings, thermostat bases for air conditioners, air conditioner panel switch boards, horn terminals, electrical component insulation plates, lamp housings, ignition device cases and other automotive / vehicle related parts, personal computer housings, mobile phone housings, etc. A wide range of fields such as housing applications in the information and communication field, other high-dimensional accuracy, electromagnetic shielding properties, barrier plates that require barrier properties such as gas and liquid, applications that require heat and electrical conductivity, outdoor installation equipment Alternatively, it is useful for building members, and is particularly useful for automobile parts, electrical / electronic parts, thermal equipment parts, etc. that are required to be lightweight and have a high degree of freedom in shape, and are eager to replace metals.

  Hereinafter, although an example is given and the present invention is explained in detail, the gist of the present invention is not limited only to the following examples.

[Reference Example 1] (Example of production of PPS mixture as a raw material for cyclic PPS)
A production example of the PPS mixture as the raw material for the cyclic PPS described in the text (4) will be described below.

<Preparation of PPS mixture>
In a 1000 L autoclave with a stirrer, 42.7% sodium hydrosulfide 82.7 kg (700 mol), 96% sodium hydroxide 29.6 kg (710 mol), N-methyl-2-pyrrolidone (hereinafter abbreviated as NMP) In some cases, 114.4 kg (1156 mol) of sodium acetate, 17.2 kg (210 mol) of sodium acetate, and 100 kg of ion-exchanged water are gradually heated to about 240 ° C. over about 3 hours while flowing nitrogen at normal pressure. After distilling 143 kg of water and 2.8 kg of NMP through the rectification tower, the reaction vessel was cooled to 160 ° C. In addition, 0.02 mol of hydrogen sulfide per 1 mol of the sulfur component charged during this liquid removal operation was scattered out of the system.

  Next, 103 kg (703 mol) of p-dichlorobenzene and 90 kg (910 mol) of NMP were added, and the reaction vessel was sealed under nitrogen gas. While stirring at 240 rpm, the temperature was raised to 270 ° C. at a rate of 0.6 ° C./min and held at this temperature for 140 minutes. While 12.6 kg (700 mol) of water was injected over 15 minutes, it was cooled to 250 ° C. at a rate of 1.3 ° C./min. Thereafter, the slurry was cooled to 220 ° C. at a rate of 0.4 ° C./min, and then rapidly cooled to near room temperature to obtain a slurry (A). This slurry (A) was diluted with 200 kg of NMP to obtain a slurry (B).

  200 kg of the slurry (B) heated to 80 ° C. is filtered with a sieve (80 mesh, opening 0.175 mm) at a 50 kg / 1 batch scale, and about 150 kg of the slurry (C) is used as a filtrate component, and the slurry is used as a mesh-on component. 50 kg of granular PPS resin (crude PPS resin (D)) was obtained.

  150 kg of the obtained slurry (C) was charged into a devolatilizer at 50 kg / 1 batch and replaced with nitrogen, and treated at 100 to 150 ° C. under reduced pressure for 1.5 hours, and then 150 ° C. and 1 ° C. in a vacuum dryer. Time treatment gave a solid. After adding 200 kg of ion-exchanged water (1.2 times the amount of slurry (C)) to this solid, it was stirred at 70 ° C. for 30 minutes to make a slurry again. This slurry was subjected to vacuum suction filtration with a filter having an opening of 10 to 16 μm. To the obtained white cake, 200 kg of ion-exchanged water was added and stirred at 70 ° C. for 30 minutes to make a slurry again. Similarly, after suction filtration, vacuum drying was performed at 70 ° C. for 5 hours to obtain 2 kg of a PPS mixture.

  A production example of a cyclic PPS mixture using the PPS mixture obtained here will be described below.

[Reference Example 2] (Production of cyclic PPS compound)
Using 2 kg of the PPS mixture obtained by the method of Reference Example 1 and 50 kg of chloroform as a solvent, the PPS mixture and the solvent were contacted by an extraction method at a bath temperature of about 80 ° C. for 3 hours to obtain an extract. The obtained extract was in the form of a slurry partially containing solid components at room temperature. Chloroform was distilled off from the extract slurry using an evaporator and then treated at 70 ° C. for 3 hours in a vacuum dryer to obtain 840 g of a solid (42% yield based on the PPS mixture).

  The solid thus obtained was confirmed to be a compound having a phenylene sulfide skeleton from an absorption spectrum in infrared spectroscopic analysis (apparatus; FTIR-8100A manufactured by Shimadzu Corporation). In addition, mass spectrum analysis (device: Hitachi M-1200H) of components separated from high performance liquid chromatography (device; Shimadzu LC-10, column; C18, detector; photodiode array), MALDI-TOF -From the molecular weight information by MS and GPC, this solid is a mixture mainly composed of cyclic PPS having 4 to 12 repeating units shown in Table 1, and the weight fraction of cyclic PPS is about 87% and 13% is straight. The chain PPS oligomer and cyclic PPS of m = 13 or more (Mw = 2000), Tm = 226 ° C.

According to the present invention, it was found that a high-purity cyclic PPS mixture containing about 87% by weight of cyclic PPS can be obtained in high yield.

[Reference Example 3]
The cyclic PPS compound obtained in Reference Example 2 was charged into a 1 L autoclave equipped with a stirrer and replaced with nitrogen. The autoclave was heated to 300 ° C. in 1 hour. When the cyclic PPS compound was melted during the temperature increase, rotation of the stirrer was started, and the mixture was melted and heated for 30 minutes with stirring at a rotational speed of 10 rpm. Thereafter, the polymer was taken out in a gut shape from the discharge port by nitrogen pressure, and the gut was pelletized. The obtained infrared spectrum of the slightly blackish product was found to have a PPS structure. The product was completely dissolved in 1-chloronaphthalene at 210 ° C.

  As a result of analyzing the obtained pellet by GPC, it was found that PPS-1 having a weight average molecular weight of 56000 and a molecular weight distribution of 1.8 was produced. Further, the Na content of this pellet was 10 ppm, and no other alkali metals were detected. Furthermore, 5 ppm of γ-butyrolactone (γ-BL) was detected as a lactone-type compound that was a generated gas component when heated at 320 ° C./60 minutes, and 5 ppm of 4-chloro-N-methylaniline (MeAn) was detected as an aniline-type compound. Further, halogens other than chlorine were not detected.

[Reference Example 4]
<Preparation of PPS by the prior art>
About 20 liters of NMP was added to 20 kg of the crude PPS resin (D) obtained in Reference Example 1, washed at 85 ° C. for 30 minutes, and filtered through a sieve (80 mesh, opening 0.175 mm). The operation of diluting the obtained solid with 50 liters of ion exchanged water, stirring at 70 ° C. for 30 minutes, and filtering through an 80 mesh sieve to collect the solid was repeated 5 times in total. The solid thus obtained was dried with hot air at 130 ° C. to obtain a dried polymer. The absorption spectrum of the obtained polymer by infrared spectroscopic analysis was consistent with the absorption of the PPS mixture obtained in Reference Example 1.

As a result of GPC measurement of the obtained PPS-2, it was found that the obtained PPS-2 had a weight average molecular weight of 59600 and a dispersity of 3.8. Further, as a result of elemental analysis, the Na content was 1040 ppm. Further, the PPS obtained in Reference Example 3 was analyzed for the generated gas components during heating, and as a result, 618 ppm of γ-butyrolactone and 416 ppm of 4-chloro-N-methylaniline were detected with respect to the weight of PPS before heating. It was done. Here, alkali metals other than Na and halogens other than chlorine were not detected.

[Reference Example 5]
<Preparation of PPS by the prior art>
In a 20 liter autoclave with a stirrer and a valve at the bottom, 2383 g (20.0 mol) of 47% sodium hydrosulfide (Sankyo Kasei), 831 g (19.9 mol) of 96% sodium hydroxide, N-methyl-2 -3960 g (40.0 mol) of pyrrolidone (NMP) and 3000 g of ion-exchanged water were charged, gradually heated to 225 ° C over about 3 hours while flowing nitrogen at normal pressure, and after distilling 4200 g of water and 80 g of NMP, The reaction vessel was cooled to 160 ° C. The residual water content in the system per mole of the alkali metal sulfide charged was 0.17 mole. The amount of hydrogen sulfide scattered per mole of the alkali metal sulfide charged was 0.021 mol.

  Next, 2942 g (20.0 mol) of p-dichlorobenzene (Sigma Aldrich) and 1515 g (15.3 mol) of NMP were added, and the reaction vessel was sealed under nitrogen gas. Then, while stirring at 400 rpm, the temperature was increased from 200 ° C. to 227 ° C. at a rate of 0.8 ° C./min, then increased to 274 ° C. at a rate of 0.6 ° C./min, and held at 274 ° C. for 50 minutes. Then, the temperature was raised to 282 ° C. Open the extraction valve at the bottom of the autoclave, pressurize with nitrogen, flush the contents into a vessel with a stirrer over 15 minutes, stir at 250 ° C for a while to remove most of the NMP, polyphenylene sulfide (PPS) and Solids containing salts were collected.

  The obtained solid and 15120 g of ion-exchanged water were placed in an autoclave equipped with a stirrer, washed at 70 ° C. for 30 minutes, and suction filtered through a glass filter. Next, 17280 g of ion-exchanged water heated to 70 ° C. was poured into a glass filter, and suction filtered to obtain a cake.

  The obtained cake, 11880 g of ion-exchanged water and 12 g of acetic acid were charged into an autoclave equipped with a stirrer, and the inside of the autoclave was replaced with nitrogen, and then the temperature was raised to 192 ° C. and held for 30 minutes. Thereafter, the autoclave was cooled and the contents were taken out.

  The contents were subjected to suction filtration with a glass filter, and then 17280 g of ion-exchanged water at 70 ° C. was poured into the contents, followed by suction filtration to obtain a cake. The obtained cake was dried with hot air at 80 ° C., and further dried under vacuum at 120 ° C. for 24 hours to obtain dry PPS. Subsequently, it processed at 220 degreeC for 5 hours, passing nitrogen through a dryer. The obtained PPS-3 had a polystyrene equivalent weight average molecular weight of 20000 and a dispersity of 3.8. Moreover, Na content of obtained PPS-3 was 980 ppm, and the alkali metal other than this was not detected. Furthermore, 420 ppm of γ-butyrolactone (γ-BL) was detected as a lactone type compound that was a generated gas component when heated at 320 ° C. for 60 minutes, and 775 ppm of 4-chloro-N-methylaniline (MeAn) was detected as an aniline type compound. . Further, halogens other than chlorine were not detected.

[Reference Example 6] Inorganic filler carbon fiber (CF): MLD300 (fibrous filler, fiber diameter 7 μm, manufactured by Toray Industries, Inc.) Average fiber length 150 μm.
Graphite (CFW-1): CFW50A (manufactured by Chuetsu Graphite Co., Ltd.) Average particle size of 48 μm.
Graphite (CFW-2): CFW18A (manufactured by Chuetsu Graphite Co., Ltd.) Average particle diameter of 18 μm.
Alumina (Al-1): EA-10 (manufactured by Sumitomo Chemical Co., Ltd.) Average particle size 17 μm.
Alumina (Al-2): Al-32B (manufactured by Sumitomo Chemical Co., Ltd.) Average particle size of 2.9 μm.

[Reference Example 7] Additive (uses 42 mesh pass through sieve)
HWE: Montanate ester wax “Lico Wax” E (manufactured by Clariant Japan)
PX: PX-200 (Powdered aromatic condensed phosphate ester, CAS No. 139189-30-3, manufactured by Daihachi Chemical Industry Co., Ltd.) Melting point 95 ° C. (uses 42 mesh pass through sieve).

Examples 1 to 4, Comparative Examples 1 and 2
Tsukishima Kikai's rotary punching equipped with an automatic raw material supply feeder by blending the polyarylene sulfide of Reference Examples 3 to 5, the inorganic filler shown in Reference Example 6 and the additive of Reference Example 7 in the amounts shown in Table 2 using a Henschel mixer. A 6 mm diameter × 3 mm long cylindrical tablet (tablet resin composition) (maximum value 6 mm, minimum value 3 mm) was obtained by tableting at room temperature using a tablet machine. Subsequently, after drying with a hot air dryer at 140 ° C. for 3 hours, the following evaluation was performed.

Example 5
The cyclic PPS compound obtained in Reference Example 2 was charged into a 1 L autoclave equipped with a stirrer so as to have the same composition as in Example 3 (PPS; 39% by volume, alumina; 61% by volume) and replaced with nitrogen. . The autoclave was heated to 300 ° C. in 1 hour. When the cyclic PPS compound was melted during the temperature increase, rotation of the stirrer was started, and the mixture was melted and heated for 30 minutes with stirring at a rotational speed of 10 rpm. Thereafter, the polymer was taken out in a lump by nitrogen pressure and pulverized to obtain a lump that passed through a 3 mmφ mesh. The obtained infrared spectrum of the slightly blackish product was found to have a PPS structure. The product was dissolved in 1-chloronaphthalene except that alumina remained at 210 ° C.

  The obtained crushed material was filtered with alumina and analyzed by GPC. As a result, it was found that PPS-4 having a weight average molecular weight of 56000 and a molecular weight distribution of 1.8 was produced. Further, the Na content of this pellet was 10 ppm, and no other alkali metals were detected. Furthermore, 5 ppm of γ-butyrolactone (γ-BL) was detected as a lactone-type compound that was a generated gas component when heated at 320 ° C./60 minutes, and 5 ppm of 4-chloro-N-methylaniline (MeAn) was detected as an aniline-type compound. Further, halogens other than chlorine were not detected.

  The following evaluation was performed using the obtained PPS-4.

1. Molecular weight measurement The molecular weight measurement of the PPS resin obtained in the reference example was calculated in terms of polystyrene by gel permeation chromatography (GPC) which is a kind of size exclusion chromatography (SEC). The measurement conditions for GPC are shown below.
Equipment: Senshu Science SSC-7100
Column name: Senshu Science GPC3506
Eluent: 1-chloronaphthalene detector: differential refractive index detector Column temperature: 210 ° C
Pre-constant temperature: 250 ° C
Pump bath temperature: 50 ° C
Detector temperature: 210 ° C
Flow rate: 1.0 mL / min
Sample injection amount: 300 μL (slurry: about 0.2% by weight).

2. Melting | fusing point of cyclic | annular PAS compound It measured using DSC7 made from Perkin Elmer. Under the following measurement conditions, the crystallization temperature Tc was 1st Run, and the melting point Tm was 2nd Run.
First Run
・ 50 ℃ × 1 minute hold ・ Temperature increase from 50 ℃ to 320 ℃, temperature increase rate 20 ℃ / min ・ 320 ℃ × 1 minute Temperature decrease from hold 320 ℃ to 100 ℃, temperature decrease rate 20 ℃ / min Second Run
・ 100 ° C. × 1 minute Hold 100 ° C. to 320 ° C., heating rate 20 ° C./min (the melting peak temperature at this time is Tm).

3. Quantification of alkali metal content The alkali metal content in the PPS obtained in the reference example was quantified as follows.
(A) The sample was weighed in a quartz crucible and incinerated using an electric furnace.
(B) After the ashed product was dissolved with concentrated nitric acid, the volume was adjusted to a constant volume with diluted nitric acid.
(C) The obtained constant volume solution was subjected to ICP gravimetric analysis (apparatus; 4500 manufactured by Agilent) and ICP emission spectroscopic analysis (apparatus; Optima 4300DV manufactured by PerkinElmer).

4). Determination of halogen content The amount of halogen in the PPS obtained in the Reference Example was determined by the following method.
(A) The sample was burned in a flask filled with oxygen.
(B) Absorbing liquid was prepared by absorbing combustion gas into the solution.
(C) A part of the absorbing solution was analyzed by ion chromatography (apparatus; DX320 manufactured by Dionex), and the halogen concentration was quantified.

5. Analysis of gas components generated during heating The components generated when the PPS obtained in the Reference Example was heated were quantified by the following method.

(A) Collection of gas generated during heating Approximately 10 mg of the molded products obtained in Examples and Comparative Examples were heated at 320 ° C. under a nitrogen stream (50 ml / min) for 60 minutes, and the generated gas components were collected in the atmosphere. The product was collected in a heat desorption tube carbotrap 400.

(B) Analysis of gas component The gas component collected in the tube was thermally desorbed by raising the temperature from room temperature to 280 ° C. for 5 minutes using a thermal desorption device TDU (manufactured by Supelco). The thermally desorbed component was divided into components using gas chromatography, and γ-butyrolactone and 4-chloro-N-methylaniline in the gas were quantified.

6). Fluidity The lowest possible filling of a 100 × 100 × 1 mm thick (film gate) corner forming product under the resin temperature and mold temperature conditions shown in Table 2 using an injection molding machine UH1000 (manufactured by Nissei Plastic Industry Co., Ltd.). The pressure was measured.

7). Bending strength Using an injection molding machine UH1000 (manufactured by Nissei Plastic Industry Co., Ltd.), a corner forming product having a thickness of 100 × 100 × 3 mm (film gate) at a minimum pressure of +5 MPa under the resin temperature and mold temperature conditions shown in Table 2 Molding was performed, and two sheets were cut from the center in the flow direction to a width of 12.7 mm, and bending strength was measured in accordance with ASTM D790.

8). Dimensional stability (linear expansion coefficient)
Using an injection molding machine UH1000 (manufactured by Nissei Plastic Industrial Co., Ltd.), a test piece having a thickness of 80 mm × 80 mm × 2 mm is prepared at the resin temperature and mold temperature shown in Table 2, and the length is 10 mm in the flow direction from the center of the molded product. X A prismatic molded product having a width of 1 mm x 2 mm was cut out and measured at 100 ° C to 230 ° C (5 ° C / min) using TMA (manufactured by Seiko Denshi).

9. Mold corrosiveness Precipitation hardened steel (NAK80; manufactured by Daido Special Steel Co., Ltd.) on the movable side of the mold under the resin temperature and mold temperature conditions shown in Table 1 using an injection molding machine UH1000 (manufactured by Nissei Plastic Industrial Co., Ltd.) Inserted a metal insert to obtain an 80 × 80 × 2 mm thick (film gate) square-shaped product made of the above, and observed the cloudiness of the surface when forming 3000 shots. The evaluation was as follows: No change; ○, Corrosion and surface whitening; x.

10. Particle size distribution of filler The inorganic filler of Reference Example 6 was blended with a Hensial mixer with the same composition as in Examples and Comparative Examples, and about 0.05 g of the obtained inorganic filler was placed in 50 cc of water and stirred. Add a few drops of surfactant solution (a small amount of foam) to 100cc of “My Pet” (Kao Corporation) in advance and disperse with an ultrasonic cleaner, then Shimadzu Corporation The amount of particles (%) in each particle diameter section is plotted using a laser diffraction particle size distribution analyzer SALD-3100, and D10 (10% portion of the total particle size distribution; small diameter), D50 from the accumulated distribution curve. (Average particle size), D90 (90% portion of the total particle size distribution; large particle size) was measured.

  As is apparent from the results in Table 2, the highly filled resin composition of the present invention has a weight average molecular weight (Mw) of 10,000 or more and a dispersity represented by weight average molecular weight / number average molecular weight (Mn) of 2. By using a polyarylene sulfide of 5 or less, it becomes possible to obtain a highly filled filler having good molding processability (good flow), and a characteristic approximating the filler characteristic used in a thermoplastic resin that has not been obtained conventionally can be obtained, and It can be seen that the strength, which is a problem of high filler filling, is improved. In addition, since the corrosiveness of molds, which was a problem during continuous production, can be improved, it will be expanded to automotive parts, electrical / electronic parts, thermal equipment parts, etc. where metal replacement is eagerly desired for weight reduction. It becomes possible.

Claims (7)

(A) The weight average molecular weight (Mw) is 10,000 or more and the dispersity represented by the weight average molecular weight / number average molecular weight (Mn) is 2.5 or less. A filler high-filling resin composition comprising 5 to 50% by volume of polyarylene sulfide and (b) 95 to 50% by volume of an inorganic filler ,
(A) Polyarylene sulfide is
(I) It is obtained by melting and heating a cyclic polyarylene sulfide mixture represented by the following general formula (1),
(Ii) the alkali metal content is 100 ppm or less,
(Iii) The lactone type compound in the generated gas component when heated at 320 ° C. for 60 minutes in a non-oxidizing atmosphere is 500 ppm or less based on the weight of the polyarylene sulfide, and the aniline type compound is 300 ppm or less based on the weight of the polyarylene sulfide. A filler high-filling resin composition.

(M may be an integer of 4 to 20, m may be a mixture of 4 to 20) 2. The highly filled filler resin composition according to claim 1, wherein (a) polyarylene sulfide obtained by melting and heating the cyclic polyarylene sulfide mixture in the absence of an ionic ring-opening polymerization catalyst is used. . (B) A ratio (D90 / D10) of 90% cumulative particle size (D90) and 10% cumulative particle size (D10) obtained from the cumulative particle size distribution curve of the inorganic filler is 10 or more. Or the filler high filling resin composition of 2. The method for producing a highly filled resin composition according to any one of claims 1 to 3, wherein the cyclic polyphenylene sulfide mixture represented by the following general formula (1) and the inorganic filler (b) are melted and heated.

Furthermore, (c) one or more of fatty acid metal salts, ester compounds, amide group-containing compounds, epoxy compounds, and phosphate esters are added to 100 parts by weight of the total amount of (a) and (b). The filler high-filling resin composition according to any one of claims 1 to 3, comprising 5 to 10 parts by weight. A method for producing a tablet comprising a highly filled resin composition with a filler, wherein the highly filled resin composition according to any one of claims 1 to 5 is compressed into a tablet. A molded article obtained by injection molding the highly filled resin composition according to any one of claims 1 to 5.