JP5970793B2 - Resin composition, method for producing the same, molded product, and method for producing the same - Google Patents

Description

  The present invention relates to a resin composition and a molded product thereof, in particular, a blow hollow molded product and a material for the molded product.

  In recent years, a method for producing ducts in an engine room by blow hollow molding has become widespread as an automobile part. Currently, polyamide-based materials are mainly used, but polyamide-based materials have insufficient heat resistance. In addition, there is a need for blow hollow molding materials that have high heat resistance and also have chemical resistance and impact resistance.

  On the other hand, polyarylene sulfide resin (hereinafter referred to as “PAS resin”) is an engineering plastic having excellent heat resistance, chemical resistance, flame retardancy, and electrical properties, There is an increasing demand for applications such as automotive parts and precision machine parts.

  Various blow hollow molding materials using PAS resin have been tried for a long time, but when molding PAS resin, its melt fluidity is very high, so ordinary extrusion blow molding, that is, extruding parison. The blow molding method has a problem that the drawdown of the parison is very large and it is extremely difficult to mold into a container with less uneven thickness. For this reason, most of them are limited to injection molding, and most of the PPS resin moldings are small, and for example, they are not widely applied to large parts such as bottles and tanks by blow molding. there were.

  As an application example of PAS resin to blow molding, a resin composition obtained by melt-kneading a PAS resin and an epoxy group-containing olefin copolymer is known (Patent Document 1). However, the PAS resin is a PAS resin having a high melt viscosity but a large proportion of terminal carboxy groups and a large amount of low molecular weight components. For this reason, there is not only room for improvement in the moldability of the composition such as drawdown resistance and uneven thickness when blow hollow molding is performed, but in particular, the low molecular weight component of the PAS resin and the epoxy group-containing olefin copolymer. Since the ratio of the reaction product with the coalescence becomes high, there is room for improvement in mechanical strength, particularly resistance to thermal shock, and it has not been used in more severe environments such as around automobile engines.

JP-A-3-236930

  Therefore, the problem to be solved by the present invention is to use a polyarylene sulfide resin to provide a molded product excellent in mechanical strength, particularly cold shock resistance, and an excellent moldability for providing the molded product. It is providing the resin composition which has, and its manufacturing method.

In order to solve the above-mentioned problems, the present inventors have conducted intensive studies, and as a result, polyarylene sulfide resin having a specific terminal carboxy group has an epoxy group-containing olefin copolymer having a specific range of epoxy equivalents. In combination, a polyarylene sulfide resin composition for a molded article excellent in mechanical strength such as cold and thermal shock resistance, particularly a molded article and a molded article excellent in moldability, and a method for producing the same are obtained. As a result, the present invention has been completed. That is, the present invention
It has a carboxyl group at a terminal ratio of 25 to 45 [μmol / g], a non-Newtonian index of 0.90 to 1.15, and a melt viscosity measured at 300 ° C. of 1,000 poise to 3,000. A polyarylene sulfide resin (A) in the range of poise and an epoxy group-containing polyolefin (B) having an epoxy equivalent in the range of 3,000 to 20,000 [g / eq] the method for producing a de-resin (a) a resin composition wherein per 100 parts by weight characterized by melt mixing kneaded so that the ratio of 5 to 30 parts by weight. The present invention has a terminal carboxyl group at a rate of 25 to 45 [μmol / g], a non-Newtonian index of 0.90 to 1.15, and a melt viscosity measured at 300 ° C. of 1,000 poise. The polyarylene sulfide resin (A) in the range of ˜3,000 poise and the epoxy group-containing polyolefin (B) in which the epoxy equivalent is in the range of 3,000 to 20,000 [g / eq], polyarylene sulfide fit de resin (a) the polyolefin (B) is a resin composition obtained by melt mixing kneaded so that the ratio of 5 to 30 parts by weight to 100 parts by weight related.

  According to the present invention, using a polyarylene sulfide, a hollow molded article excellent in mechanical strength such as cold thermal shock resistance, particularly a blow hollow molded article, and a moldability for providing the blow hollow molded article It is possible to provide an excellent resin composition and a method for producing the same.

The method for producing the resin composition of the present invention has a carboxyl group at the terminal at a ratio of 25 to 45 [μmol / g], a non-Newtonian index of 0.90 to 1.15, and measurement at 300 ° C. Polyarylene sulfide resin (A) having a melt viscosity in the range of 1,000 poise to 3,000 poise, and an epoxy group-containing polyolefin having an epoxy equivalent in the range of 3,000 to 20,000 [g / eq] and (B), the polyarylene sulfide fit de resin (a) the polyolefin with respect to 100 parts by weight (B), characterized in that the melt mixing kneaded so that the ratio of 5 to 30 parts by weight.

  The polyarylene sulfide resin (A) used in the present invention contains a carboxyl group at the terminal at a ratio of 25 to 45 (μmol / g) in the resin. When the terminal carboxy group is less than 25 (μmol / g), the reactivity with the epoxy group contained in the polyolefin (B) becomes insufficient, and the desired effects such as mechanical strength such as thermal shock resistance are exhibited. On the other hand, if it exceeds 45 (μmol / g), the reactivity with the polyolefin becomes excessive, it becomes easy to gel during melt kneading, and the melt viscosity becomes excessive. It decreases and it becomes difficult to obtain a uniform molded product without uneven thickness.

The polyarylene sulfide resin (A) preferably has a melt viscosity in a range suitable for blow molding, and usually has a melt viscosity of 1,000 to 3, at 300 ° C. and a shear rate of 10 sec ⁻¹ . It is preferable to use a high molecular weight type of 000 poise, more preferably 1500 to 3000 poise. If the melt viscosity is less than 1000 poise, drawdown is likely to occur. On the other hand, if it exceeds 3000 poise, the extrusion stability of the parison decreases and it becomes difficult to obtain a uniform molded product with no uneven thickness.
Furthermore, the polyarylene sulfide resin (A) has a non-Newtonian index in the range of 0.90 to 1.15, and has a so-called linear structure. If the non-Newtonian index exceeds 1.15, the degree of branching is high, and the proportion of terminal carboxy groups cannot be adjusted to an appropriate range.
As described above, the polyarylene sulfide resin used in the present invention has a high melt viscosity particularly suitable for blow hollow molding, and the non-Newton index is 0.90 to 1. Since it has a linear structure with a low branching degree of 15, the proportion of terminal carboxy groups can be suppressed, and the melt viscosity of the melt-kneaded product reacts excessively with the epoxy group contained in the polyolefin (B). It is possible to prevent an increase in the thickness, to exhibit excellent moldability without uneven thickness, and to improve the mechanical strength of the blown hollow molded product, in particular, the thermal shock resistance. Furthermore, since the compatibility with the polyolefin (B) is improved and the moldability and the thermal shock resistance are further improved, the alkali metal salt in the resin (A) is used at a ratio of 20 μmol / g or less in the resin. It is preferable.

  The polyarylene sulfide resin (A) used in the present invention can be produced, for example, by the following method. That is, in the presence of a solid alkali metal sulfide and an aprotic polar organic solvent, the polyhaloaromatic compound (a), the alkali metal hydrosulfide (b) and the organic acid alkali metal salt (c) The organic acid alkali metal salt (c) is used in a proportion of 0.01 mol or more and less than 0.9 mol with respect to a total of 1 mol of the alkali metal sulfide and alkali metal hydrosulfide (b), and in the reaction system To produce a crude polyarylene sulfide resin by reacting under the condition that the water content existing in 1 is 0.02 mol or less with respect to 1 mol of the aprotic polar organic solvent, and then deionizing Is obtained.

The proportion of the organic acid alkali metal salt (c) in the reaction system is 0.01 mol or more and less than 0.9 mol with respect to 1 mol of sulfur atoms present in the reaction system. The range of 04 to 0.4 mol is preferable in that the effect of suppressing side reactions becomes remarkable.
The organic acid alkali metal salt (c) is preferably an alkali metal salt (c2) of a hydrolyzate of the aliphatic cyclic compound (c1) from the viewpoint of good reactivity, and N-methyl-2-pyrrolidone, N- Alkali metal salts of ring-opened products of aliphatic cyclic amide compounds such as cyclohexyl-2-pyrrolidone, 2-pyrrolidone, 1,3-dimethyl-2-imidazolidinone, ε-caprolactam, N-methyl-ε-caprolactam More preferred is an alkali metal salt of a hydrolyzate of N-methyl-2-pyrrolidone, from the viewpoint of reactivity. These alkali metal salts are preferably used as lithium salts and sodium salts, and sodium salts are particularly preferable.

  Examples of the aprotic polar organic solvent include NMP, N-cyclohexyl-2-pyrrolidone, N-methyl-ε-caprolactam, formamide, acetamide, N-methylformamide, N, N-dimethylacetamide, 2-pyrrolidone, ε-caprolactam, hexamethylphosphoramide, tetramethylurea, N-dimethylpropyleneurea, amidourea of 1,3-dimethyl-2-imidazolidinone acid, and lactam; sulfolanes such as sulfolane and dimethylsulfolane; benzonitrile and the like Nitriles; ketones such as methyl phenyl ketone and mixtures thereof.

As a more specific manufacturing process of the polyarylene sulfide resin (A) used in the present invention, a method through the following processes 1 to 4 can be mentioned.
Step 1: Aliphatic cyclic compound (c1) capable of ring opening by hydrolysis with hydrous alkali metal sulfide or hydrous alkali metal hydrosulfide and alkali metal hydroxide in the presence of a non-hydrolyzable organic solvent And producing a slurry (I) containing solid alkali metal sulfide by reacting while dehydrating,
Step 2: After the production of the slurry (I), a step of further adding an aprotic polar organic solvent, distilling off water to perform dehydration,
Step 3: Next, in the slurry (I) obtained through the dehydration step of Step 2, the polyhaloaromatic compound (a), the alkali metal hydrosulfide (b), and the hydrolyzate of the compound (c1) A step of polymerizing the alkali metal salt (c2) of 1 mol of the aprotic polar organic solvent with a water content existing in the reaction system of 0.02 mol or less.
Process 4: The process of deionizing the polymer (crude polyarylene sulfide resin) obtained in Process 3 is an essential production process.

  Step 1 includes a hydrous alkali metal sulfide, or a hydrous alkali metal hydrosulfide and an alkali metal hydroxide, an aliphatic cyclic compound (c1) that can be ring-opened by hydrolysis, a non-hydrolyzable organic solvent, Is a step of producing slurry (I) by reacting while dehydrating.

  Examples of the hydrated alkali metal sulfide used in Step 1 include liquid or solid hydrates of compounds such as lithium sulfide, sodium sulfide, potassium sulfide, rubidium sulfide, cesium sulfide, and the solid content concentration thereof is 10 to 80 mass. %, Particularly 35 to 65% by mass.

  On the other hand, the hydrated alkali metal hydrosulfide includes, for example, liquid or solid hydrates of compounds such as lithium hydrosulfide, sodium hydrosulfide, potassium hydrosulfide, rubidium hydrosulfide, and cesium hydrosulfide. Is preferably 10 to 80% by mass. Among these, hydrated lithium hydrosulfide and hydrated sodium hydrosulfide are preferable, and hydrated sodium hydrosulfide is particularly preferable.

  Examples of the alkali metal hydroxide include lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide, cesium hydroxide, and aqueous solutions thereof. In addition, when using this aqueous solution, it is preferable that it is an aqueous solution with a density | concentration of 20 mass% or more from the point that the spin-drying | dehydration process of the process 1 is easy. The amount of alkali metal hydroxide used is preferably in the range of 0.8 to 1.2 moles per mole of alkali metal hydrosulfide (b) from the viewpoint of promoting the production of solid alkali metal sulfide. In particular, the range of 0.9 to 1.1 mol is more preferable.

More specifically, the method of performing the dehydration process in Step 1 includes the following methods.
(Method 1-A) Aliphatic cyclic compound (c1) capable of ring opening by hydrolysis, non-hydrolyzable organic solvent, hydrous alkali metal sulfide, and further, if necessary, the alkali metal hydrosulfide or alkali metal water A predetermined amount of oxide is charged into a reaction vessel, and the temperature is equal to or higher than the boiling point of the hydrated alkali metal sulfide and water is removed by azeotropic distillation, specifically in the range of 80 to 220 ° C, preferably 100 to 200 ° C. The method of dehydrating by heating to the range.
(Method 1-B) A predetermined amount of an aliphatic cyclic compound (c1) that can be ring-opened by hydrolysis, a non-hydrolyzable organic solvent, a hydrous alkali hydrosulfide, and an alkali metal hydroxide is charged into a reaction vessel. After the hydrated alkali metal sulfide is produced almost simultaneously with the preparation, the temperature is equal to or higher than the boiling point of the hydrated alkali metal sulfide and the water is removed by azeotropic distillation, specifically in the range of 80 to 220 ° C. A method of dehydrating by heating to a range of preferably 100 to 200 ° C.

  In the above method 1-A and method 1-B, azeotropic distillation of water and non-hydrolyzable organic solvent is separated with a decanter, and only the non-hydrolyzable organic solvent is returned to the reaction system or azeotropic distillation is performed. An additional amount of the non-hydrolyzable organic solvent corresponding to the amount that has been added may be added, or an excess of the non-hydrolyzable organic solvent that is azeotropically distilled off or more may be charged in advance.

The reaction system in the initial stage of dehydration consists of two layers of an organic layer and an aqueous layer. As dehydration proceeds, anhydrous alkali metal sulfide precipitates in the form of fine particles, resulting in a non-hydrolyzable organic layer. Disperse uniformly in the solvent. Further, dehydration is continued until almost all of the aliphatic cyclic compound (c1) that can be opened by hydrolysis in the reaction system is hydrolyzed.
The total amount of water in the reaction system after the dehydration treatment in step 1 is preferably as small as possible. Specifically, it exceeds 0.1 mol per mole of sulfur atoms in the reaction system and is 0.99 mol or less. The ratio is such that the amount of water existing in the reaction system is 0.03 to 0.11 mol per mol of sulfur atoms in the reaction system, particularly in the range of 0.6 to 0.96 mol. It is preferable that Here, “the amount of water existing in the reaction system” means water excluding the water consumed for hydrolysis of the compound (c1) out of the total amount of water in the reaction system, that is, crystal water, H _2. O or the like refers to the total amount of moisture actually present in the reaction system (hereinafter referred to as “crystal water or the like”).

The amount of the aliphatic cyclic compound (c1) charged in Step 1 is 0.01 with respect to 1 mol of the hydrated alkali metal hydrosulfide (Method 1-A) or the hydrated alkali metal hydrosulfide (Method 1-B). It is preferable to use it in the ratio which becomes more than mol and less than 0.9 mol. In particular, 0.04 to 0.4 mol with respect to 1 mol of the hydrated alkali metal hydrosulfide (Method 1-A) or the hydrated alkali metal hydrosulfide (Method 1-B) from the point that such an effect becomes remarkable. It is preferable to use in the ratio which becomes.
The alkali metal salt of the hydrolyzate of the aliphatic cyclic compound (c1) may be a lithium salt, sodium salt, potassium salt, rubidium salt or cesium salt of the hydrolyzate of the aliphatic cyclic compound (c1). Is mentioned. These organic acid alkali metal salts (c2) are preferably in a liquid state in the reaction system.
Among the above-mentioned organic acid alkali metal salts (c2), the alkali metal salt (c2) of the hydrolyzate of the aliphatic cyclic compound (c1) is preferable from the viewpoint of good reactivity, and the aliphatic cyclic amide compound. An alkali metal salt of a ring-opened product, particularly an alkali metal salt of a hydrolyzate of NMP is preferable from the viewpoint of reactivity. These alkali metal salts are preferably used as lithium salts and sodium ion salts.
Further, the non-hydrolyzable organic solvent used in step 1 may be any organic solvent that is inert to water as described above. For example, general-purpose aliphatic hydrocarbons and aromatic hydrocarbons can be used. However, in the present invention, in particular, the use of the polyhaloaromatic compound (a) subjected to the reaction in Step 3 as the organic solvent improves the reaction or polymerization in the next Step 3 and dramatically improves production efficiency. This is preferable.

  Examples of the polyhaloaromatic compound (a) used here include p-dihalobenzene, m-dihalobenzene, o-dihalobenzene, 1,2,3-trihalobenzene, 1,2,4-trihalobenzene, 1,3,5. -Trihalobenzene, 1,2,3,5-tetrahalobenzene, 1,2,4,5-tetrahalobenzene, 1,4,6-trihalonaphthalene, 2,5-dihalotoluene, 1,4-dihalonaphthalene 1-methoxy-2,5-dihalobenzene, 4,4′-dihalobiphenyl, 3,5-dihalobenzoic acid, 2,4-dihalobenzoic acid, 2,5-dihalonitrobenzene, 2,4-dihalo Nitrobenzene, 2,4-dihaloanisole, p, p'-dihalodiphenyl ether, 4,4'-dihalobenzophenone, 4,4'-dihalodiphenyl sulfone, 4, '- dihalodiphenyl sulfoxide, 4,4'-dihalodiphenyl sulfide, and a compound having an aromatic ring in the alkyl group having 1 to 18 carbon atoms of each of the above compounds as nuclear substituents. Moreover, it is desirable that the halogen atom contained in each compound is a chlorine atom or a bromine atom.

  The amount of the non-hydrolyzable organic solvent used is not particularly limited, but is preferably an amount that improves the fluidity of the slurry (I) obtained in Step 1. Further, when the polyhaloaromatic compound (a) is used as the non-hydrolyzable organic solvent, the hydrated alkali metal sulfide (Method 1-A) or the hydrated alkaline water is used from the viewpoint of excellent reactivity and polymerizability in Step 2. The range of 0.2 to 5.0 mol is preferable per mol of sulfide (Method 1-B), and the range of 0.3 to 2.0 mol is particularly preferable. The polyhaloaromatic compound (a) can be used as it is in the subsequent production process of the PAS resin, and may be additionally used if necessary in the subsequent production process of the crude polyarylene sulfide resin. However, if it is excessive, it may be used after being reduced.

  In addition, a copolymer containing two or more different reaction units can be obtained by appropriately selecting and combining polyhaloaromatic compounds (a). For example, p-dichlorobenzene and 4,4′-dichlorobenzophenone Alternatively, it is particularly preferable to use 4,4′-dichlorodiphenylsulfone in combination since polyarylene sulfide having excellent heat resistance can be obtained.

More specifically, the dehydration treatment in the step 2 is more preferably performed after the slurry (I) is formed in the step 1, and more preferably the abundance of crystal water and the like in the slurry (I) is the sulfur atom 1 in the reaction system. After reaching a ratio of 0.03 to 0.11 mole per mole, as step 2, an aprotic polar organic solvent is added to the reaction system to perform dehydration. At this time, the amount of the aprotic polar organic solvent to be added is a ratio of 0.5 to 5 moles per mole of sulfur atoms present in the reaction system. This is preferable because the crystal water and the like can be efficiently extracted into the solution. The dehydration process in step 2 is usually performed under conditions of a temperature of 180 to 220 ° C. and a gauge pressure of 0.0 to 0.1 MPa, particularly a temperature of 180 to 200 ° C. and a gauge pressure of 0.0 to 0.05 MPa. However, it is preferable because it is excellent in dehydration efficiency and can suppress generation of a side reaction that inhibits polymerization. Specifically, a mixture of an aprotic polar organic solvent and water is isolated by distillation under the temperature and pressure conditions described above, and this mixed vapor is condensed with a condenser, separated with a decanter, etc. A method of returning the aromatic compound (a) into the reaction system can be mentioned. Here, the amount of water existing in the reaction system at the start of Step 3 is 0.02 mol or less with respect to 1 mol of the aprotic polar organic solvent in the reaction system, and the sulfur atom present in the reaction system. The ratio is less than 0.02 mol, more preferably less than 0.01 mol per mol, and in the case of exceeding this, by-products that inhibit polymerization in the reaction / polymerization step of step 3 are generated. Will occur. From this point, specifically, the amount of water present in the reaction system at the start of Step 3 is preferably 0.02 mol or less with respect to 1 mol of the aprotic polar organic solvent in the reaction system.
In addition, as an aprotic polar organic solvent added at the process 2, the above-mentioned thing can be used, Among these, NMP is especially preferable.

Next, in step 3 of the present invention, in the slurry (I) obtained through the dehydration step of step 2, the polyhaloaromatic compound (a), the alkali metal hydrosulfide (b), and the compound (c1) ) And the alkali metal salt (c2) of the hydrolyzate to cause polymerization.
In the present invention, the hydrolysis of the polyhaloaromatic compound (a), the alkali metal hydrosulfide (b), and the compound (c1) in the presence of the solid alkali metal sulfide and the aprotic polar organic solvent as described above. The decomposition product is characterized in that the alkali metal salt (c2) of the decomposition product is reacted in the state of a slurry and with the amount of water in the reaction system reduced as much as possible. In the present invention, by performing a heterogeneous reaction using a sulfidizing agent as a solid content in the reaction system in this way, side reactions can be suppressed and the molecular weight of the crude polyarylene sulfide resin can be increased. .

In the above reaction, the organic acid alkali metal salt (c2) is present in an amount of 0.01 mol or more and less than 0.9 mol, particularly 0.04 to 0.4 mol, relative to 1 mol of sulfur atoms present in the reaction system. It is preferable from the viewpoint that the effect of suppressing side reactions becomes remarkable.
The polyhaloaromatic compound (a) in the reaction of Step 3 may be added to the reaction system in Step 2, but as described above, in Step 1, the polyhaloaromatic compound (a) is used as a non-hydrolyzable organic solvent. When used, the reaction of step 2 can be performed as it is.
In addition, the alkali metal hydrosulfide (b) can be subjected to the reaction in the step 2 by using the alkali metal hydrosulfide (b) present in the slurry (I) through the step 3 as it is.
In Step 3, a lithium salt compound such as lithium chloride or lithium acetate may be added to the reaction system and the reaction may be performed in the presence of lithium ions.
The lithium salt compound can be used as an anhydride, a hydrate, or an aqueous solution.

  The amount of lithium ions in the reaction system in Step 3 is 0.01 mol or more when the total number of moles of the hydrous alkali metal sulfide used in Step 1 and the sulfiding agent added thereafter is 1 mol. It is preferable that the ratio is in a range of less than .9 mol from the viewpoint that the effect of improving the reactivity in step 3 is remarkable, and in particular, the sulfur atom in which the organic acid alkali metal salt (c) is present in the reaction system. And the amount of lithium ions in the reaction system is 1.8 on a molar basis with respect to the organic acid alkali metal salt (c). It is preferable that the amount is in the range of -2.2 mol from the viewpoint that the crude polyarylene sulfide resin has a higher molecular weight.

  Alkali metal hydrosulfide (b) may be added separately at any stage of step 3. Examples of the alkali metal hydrosulfide (b) that can be used here include lithium hydrosulfide, sodium hydrosulfide, potassium hydrosulfide, rubidium hydrosulfide, cesium hydrosulfide, and hydrates thereof.

  Further, a small amount of alkali metal hydroxide may be added in order to react with alkali metal hydrosulfide (b) present in a trace amount in the alkali metal sulfide constituting the solid content of the slurry, or alkali metal thiosulfate.

A specific method for carrying out the reaction and polymerization in Step 3 is as follows. For the slurry (I) obtained through Step 1 and Step 2, a polyhaloaromatic compound (a), an alkali metal hydrosulfide (b), It is preferable to add a protic polar organic solvent and the lithium salt compound and react or polymerize in the range of 180 to 300 ° C, preferably in the range of 200 to 280 ° C. The polymerization reaction can be carried out at a constant temperature, but can also be carried out while raising the temperature stepwise or continuously.
Further, the amount of the polyhaloaromatic compound (a) in the step 3 is specifically preferably in the range of 0.8 to 1.2 mol, particularly 0.9 to 1 per mol of sulfur atom in the reaction system. A range of 1 mol is preferable from the viewpoint of obtaining a crude polyarylene sulfide resin having a higher molecular weight.
In the reaction or polymerization reaction in Step 3, an aprotic polar organic solvent may be further added. The total amount of the aprotic polar organic solvent present in the reaction is not particularly limited, but it is aprotic so as to be 0.6 to 10 moles per mole of sulfur atoms present in the reaction system. It is preferable to add a polar organic solvent, and more preferably in the range of 2 to 6 mol from the viewpoint of enabling higher molecular weight of the PAS resin. Further, from the viewpoint of increasing the reactant concentration per volume of the reaction vessel, a range of 1 to 3 moles per mole of sulfur atoms present in the reaction system is preferable.

  In the initial stage of the reaction or polymerization in step 3, the amount of water in the reaction system is substantially anhydrous. That is, the water used for the hydrolysis of the aliphatic cyclic compound (c1) in the dehydration step in Step 1 undergoes a ring-closing reaction after the solid content in the slurry disappears, Will appear. Therefore, in step 3 of the present invention, it is finally obtained that the water content in the polymerization slurry is 0.2 mass% or less when the consumption rate of the solid alkali metal sulfide is 10%. From the viewpoint of increasing the molecular weight of the resulting crude polyarylene sulfide resin.

As for the apparatus used for the processes 1 to 3 described in detail above, first, in the process 1 and the process 2, a dehydration vessel is equipped with a stirrer, a steam distillation line, a condenser, a decanter, a distillate return line, an exhaust line, and hydrogen sulfide capture. Examples thereof include a device and a dehydrating device including a heating device. In addition, the reaction vessel used in the dehydration process in Step 1 and Step 2 and the reaction or polymerization in Step 3 is not particularly limited, but a reaction vessel having a wetted part made of titanium, chromium, zirconium or the like is used. It is preferable to use it.
For each step of the dehydration treatment in step 1 and step 2 and the reaction or polymerization in step 3, normal polymerization methods such as a batch method, a batch method or a continuous method can be adopted. In both the dehydration step and the polymerization step, it is preferably performed in an inert gas atmosphere. Examples of the inert gas to be used include nitrogen, helium, neon, argon, etc. Among them, nitrogen is preferable from the viewpoint of economy and ease of handling.

Step 4 is a step of deionizing the crude polyarylene sulfide resin obtained in Step 3.
The deionization method for the reaction mixture containing the crude polyarylene sulfide resin obtained by the polymerization step is not particularly limited. For example, (1) after completion of the polymerization reaction, the reaction mixture is first left as it is, Or after adding an acid or a base, the solvent is distilled off under reduced pressure or normal pressure, and then the solid after the solvent is distilled off is washed once or twice with a solvent such as water, acetone, methyl ethyl ketone, alcohol, Further, neutralization, washing with water, filtration and drying, or (2) after completion of the polymerization reaction, the reaction mixture is mixed with water, acetone, methyl ethyl ketone, alcohol, ether, halogenated hydrocarbon, aromatic hydrocarbon, aliphatic hydrocarbon, etc. (Solvent that is soluble in the polymerization solvent used and is a poor solvent for at least polyarylene sulfide resin (A)) Or a method in which a solid product such as polyarylene sulfide resin (A) or an inorganic salt is precipitated and filtered, washed and dried, or (3) after completion of the polymerization reaction, the reaction mixture After adding a reaction solvent (or an organic solvent having an equivalent solubility with respect to a low molecular polymer) to the mixture and stirring, the low molecular weight polymer is removed by filtration, and then 1 with a solvent such as water, acetone, methyl ethyl ketone, alcohol or the like. The method of washing | cleaning once or 2 times or more, and neutralizing, washing with water, filtration, and drying after that is mentioned.
In the deionization method as exemplified in the above (1) to (3), the polyarylene sulfide resin (A) may be dried in a vacuum or in the air or in a non-nitrogen state such as nitrogen. You may carry out in an active gas atmosphere.

  The polyarylene sulfide resin (A) thus obtained can be used as it is as a blow hollow molding material or the like. However, it is heat-treated in air or oxygen-enriched air or under reduced pressure conditions for oxidative crosslinking. May be. The temperature of this heat treatment is preferably in the range of 180 ° C. to 270 ° C., although it varies depending on the target crosslinking treatment time and the atmosphere to be treated. The heat treatment may be performed in a state where the polyarylene sulfide resin (A) is melted at a temperature equal to or higher than the melting point of the PAS resin using an extruder or the like, but the polyarylene sulfide resin (A) is thermally deteriorated. Therefore, it is preferable to carry out at a melting point plus 100 ° C. or lower.

Next, the polyolefin (B) used in the present invention will be described.
The polyolefin (B) used in the present invention has an epoxy equivalent of 3,000 [g / eq] or more, preferably 6,000 [g / eq] or more, and 20,000 [g / eq] or less. Preferably it is the range of 10,000 [g / eq] or less. The polyolefin used in the present invention may be a mixture of an epoxy group-containing polyolefin (B ′) and polyolefin (B ″), or an epoxy group-containing polyolefin (B) in the epoxy equivalent range in advance. However, since it is easy to adjust the viscosity of the resin composition, it is preferable to use a mixture of polyolefin (B ′) and polyolefin (B ″) having an epoxy group.
The polyolefin (B ′) having an epoxy group is not particularly limited as long as it is an olefin polymer having an epoxy group, but a copolymer comprising an α-olefin and an α, β-unsaturated glycidyl ester is preferably used. It is done. Examples of α-olefins include ethylene, propylene, and butene-1. Specific examples of the glycidyl ester of α, β-unsaturated acid include glycidyl acrylate, glycidyl methacrylate, and glycidyl ethacrylate. The modification ratio of each monomer component with respect to the α-olefin is not particularly limited, but the modification site in the copolymer is converted to each monomer mass, and the ratio is 0 as the ratio with respect to 100 mass of the copolymer. The range of 0.5 to 10 parts by mass is preferable.
In the epoxy group-containing olefin polymer, in addition to the above-mentioned various monomer components, other olefin monomers such as methyl acrylate, methyl methacrylate, acrylonitrile, styrene, acetic acid are added within the range not impairing the effects of the present invention. Vinyl and vinyl ether may be copolymerized.
The melt viscosity of the polyolefin having an epoxy group used in the present invention is not particularly limited, but is preferably in the range of 1 to 20 poises as measured by a melt folate (temperature 190 ° C., load 2.16 kg).

  The polyolefin (B ″) is preferably a polyolefin that does not have a functional group that reacts with a carboxy group. For example, polyethylene, polypropylene, polystyrene, polyacrylate ester, polymethacrylate ester, poly-1-butene , Homopolymers such as poly 1-pentene and polymethyl pentene, ethylene-α-olefin copolymers, copolymers of ethylene to propylene and unsaturated carboxylic acids to unsaturated carboxylic esters, ethylene to propylene and unsaturated Copolymer obtained by metallizing at least part of carboxyl group of copolymer with carboxylic acid or unsaturated carboxylic acid ester, block copolymer of conjugated diene and vinyl aromatic hydrocarbon, and block copolymer thereof Among these, hydrides such as Ren -α- olefin copolymer is preferred.

The ethylene-α-olefin copolymer is a copolymer comprising ethylene and at least one α-olefin having 3 to 20 carbon atoms as constituent components. Specific examples of the α-olefin having 3 to 20 carbon atoms include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene and 1-undecene. 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicosene, 3-methyl-1-butene, 3-methyl-1 -Pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, 4-methyl-1-hexene, 4,4-dimethyl-1-hexene, 4,4-dimethyl-1-pentene, 4-ethyl -1-hexene, 3-ethyl-1-hexene, 9-methyl-1-decene, 11-methyl-1-dodecene, 12-ethyl-1-tetradecene and these See fit, and the like. Among these α-olefins, a copolymer using an α-olefin having 6 to 12 carbon atoms is more preferable because mechanical strength is improved and a reforming effect is further improved.
Although the melt viscosity of the polyolefin having no functional group used in the present invention is not particularly limited, it is in the range of 0.01 to 70 poises as measured by a melt folate (temperature 190 ° C., load 2.16 kg). Those are preferred.
The use ratio of the polyolefin (B ′) having an epoxy group and the polyolefin (B ″) having no functional group that reacts with a carboxy group is (B ′) / (B ″) = 99/1 to 50 in mass ratio. / 50 range. The polyolefin (B ″) used in the present invention is a so-called unmodified polyolefin and does not have a reactivity with a carboxy group, and thus serves as a viscosity modifier. For this reason, the resin composition of the present invention. Gelation during melt-kneading of the resin composition by adjusting the ratio of polyolefin (B ′) and (B ″) so that the melt flow rate (g / 10 min) of the resin falls within the range described later. The moldability, the drawdown resistance and the extrusion stability can be improved while suppressing the above.

  The blending ratio of the polyolefin used in the present invention is in the range of 5 to 30 parts by mass, more preferably 7 to 20 parts by mass, with respect to 100 parts by mass of the polyarylene sulfide resin (A). By adopting, it is possible to obtain a blow hollow molded product that has excellent moldability, in particular, it is difficult to draw down the parison during molding, shows good blow moldability, and has excellent heat resistance and chemical resistance. . If the blending amount of the polyarylene sulfide resin (A) exceeds 95% by mass, the blow moldability is lowered, which is not preferable. On the other hand, if it is less than 70% by mass, the heat resistance and chemical resistance are impaired.

Moreover, the resin composition obtained according to the present invention may contain various fillers in order to further improve performance such as strength, heat resistance, and dimensional stability.
As the filler, known and conventional materials can be used as long as the effects of the present invention are not impaired, and examples thereof include fillers having various shapes such as a granular shape and a fibrous shape.
Specifically, fibers such as glass fibers, carbon fibers, silane glass fibers, ceramic fibers, aramid fibers, metal fibers, potassium titanate, silicon carbide, calcium sulfate, calcium silicate, and natural fibers such as wollastonite. Can be used. Further, barium sulfate, calcium sulfate, clay, pyrophyllite, bentonite, sericite, zeolite, mica, mica, talc, attapulgite, ferrite, calcium silicate, calcium carbonate, magnesium carbonate, glass beads and the like can be used.
The filler used in the present invention is not an essential component, but more than 0 parts by weight, usually 10 parts by weight or more and 50 parts by weight or less, with respect to 100 parts by weight of the polyarylene sulfide resin, Various performances can be improved according to the purpose of the filler to be added, such as rigidity, heat resistance, heat dissipation, and dimensional stability.

In addition, the resin composition of the present invention includes various additives such as a mold release agent, a colorant, a heat stabilizer, an ultraviolet stabilizer, a foaming agent, a rust inhibitor, a flame retardant, and a lubricant as additives during molding. Depending on the application, polyester, polyamide, polyimide, polyetherimide, polycarbonate, polyphenylene ether, polysulfone, polyethersulfone, polyetheretherketone, polyetherketone, polyarylene, polyethylene , Polypropylene, polytetrafluoroethylene, polydifluoroethylene, polystyrene, ABS resin, epoxy resin, silicone resin, phenol resin, urethane resin, liquid crystal polymer and other synthetic resins, or polyolefin rubber, fluororubber, silicone rubber Elastomer, coupling agent, etc. If other necessary, it may be used as a resin composition containing an additive such as a filler.
The amount and method of use of these additives vary depending on the purpose and cannot be specified in general, but may be used as long as the effects of the present invention are not impaired. For example, the coupling agent may be used alone as an additive, or may be used after pretreatment with a filler in advance. As such a coupling agent, a coupling agent such as silane or titanium is used. Furthermore, among these, a silane coupling agent having a functional group that reacts with a carboxy group (for example, an epoxy group, an isocyanato group, an amino group, or a hydroxyl group) is preferable. Examples of such silane coupling agents include epoxy groups such as γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, and β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane. Containing alkoxysilane compound, γ-isocyanatopropyltrimethoxysilane, γ-isocyanatopropyltriethoxysilane, γ-isocyanatopropylmethyldimethoxysilane, γ-isocyanatopropylmethyldiethoxysilane, γ-isocyanatopropylethyldimethoxysilane , Γ-isocyanatopropylethyldiethoxysilane, isocyanato group-containing alkoxysilane compounds such as γ-isocyanatopropyltrichlorosilane, γ- (2-aminoethyl) aminopropylmethyldimethoxysilane, γ- ( -Aminoethyl) Amino group-containing alkoxysilane compounds such as aminopropyltrimethoxysilane and γ-aminopropyltrimethoxysilane, and hydroxyl group-containing alkoxysilane compounds such as γ-hydroxypropyltrimethoxysilane and γ-hydroxypropyltriethoxysilane. It is done. The usage-amount of a coupling agent is 0.01-1.0 mass part with respect to 100 mass parts of polyarylene sulfide resin (A), More preferably, it is the range of 0.1-0.4 mass part.

  The production method of the resin composition of the present invention is not particularly limited, and the raw material polyarylene sulfide resin (A) and the polyolefin (B) can be used in various forms such as powders, berets, strips, etc. Examples thereof include a method in which a blender, a V-blender and the like are put and dry blended, and then melt-kneaded using a Banbury mixer mixing roll, a single-screw or twin-screw extruder, a knee, and the like. Among them, a typical method is melt-kneading using a single-screw or twin-screw extruder having a sufficient kneading force.

The resin composition of the present invention thus obtained is excellent in moldability, drawdown resistance and extrusion stability, and can be used for various moldings. It can be suitably used for molding. Hereinafter, a blow hollow molding method and a blow hollow molded article using the resin composition of the present invention will be described.
In the resin composition of the present invention, for example, a resin composition pellet is put into a melt indexer having a cylinder temperature of 330 ° C. and an orifice system of 1 mm, a load of 10 kg is applied, and after 5 minutes of preheating, a melt flow rate (g / 10 minutes) ) Of 20 g / 10 min or less, preferably 15 g / 10 min or less shows a preferable drawdown resistance suitable for blow hollow moldability. Furthermore, since it is excellent in drawdown resistance and extrusion stability, the range of 3 to 10 g / 10 min is preferable, and the range of 3 to 6 g / 10 min is most preferable. If it is 20 g / 10 min or more, the variation in the thickness of the molded product becomes remarkable, which is not preferable. Conversely, if it is 3 or less, it tends to be a gel product, which is not preferable.

  The resin composition of the present invention prepared as described above is a generally known blow molding method, i.e., basically supplying the resin composition to an extruder and melt-extruding it to form a parison. It is obtained by making it into a 2- to 3-dimensional hollow molded body. Typical examples of commonly known blow molding methods include the direct blow method, the accumulator blow method, and the multidimensional blow method, and the multilayer blow molding method and exchange blow molding method used in combination with other materials. Of course, it is also possible to apply.

  The blow hollow molded article of the present invention thus obtained has excellent moldability, and heat resistance, dimensional stability, chemical resistance, impact resistance, cold heat resistance inherent in polyarylene sulfide. High performance gas such as bottles, tanks, ducts, etc., as a hollow molded product, discharged from internal combustion engines and fuel cells, such as chemical containers, air conditioning ducts, automobiles, etc. It can be widely used for ducts and pipes.

  EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples.

[Quantitative determination method of carboxy group and alkali metal salt]
The amount of the carboxyl group (a1) and its alkali metal salt (a2) contained in the polyarylene sulfide (A) was measured by the following method.
(Pretreatment) First, as a pretreatment, the polyarylene sulfide obtained in Examples and Comparative Examples was once dissolved in dimethylimidazolidinone (DMI) at 210 ° C. in an inert atmosphere, cooled, and then re-polished. Arylene sulfide was deposited. Next, the obtained slurry is thoroughly washed with ion-exchanged water many times and filtered, once adjusted to pH 2.5 or less with hydrochloric acid, and washed again with ion-exchanged water again and again. The obtained cake was dried at 120 ° C. in a hot air dryer. This was designated as sample (0), and the sample not subjected to pretreatment was designated as sample (1).

Next, the polyarylene sulfide used in each Example and Comparative Example was pressed into a disk shape with a press machine and measured with a microscopic FT-IR apparatus. Next, the relative intensity of absorption at 1705 cm ⁻¹ with respect to absorption at 2666 cm ⁻¹ of the obtained absorption was determined. Separately, a predetermined amount of p-chlorophenylacetic acid was mixed in polyarylene sulfide and obtained by plotting the relative intensity of the absorption intensity of 1705 cm ⁻¹ against the absorption intensity of 2666 cm ⁻¹ in the absorption curve obtained by the same operation. The numerical value obtained from the calibration curve was defined as the amount of carboxy group contained in the polyarylene sulfide.
Next, based on the prepared calibration curve, the contents of the carboxyl group and the alkali metal salt in the measurement sample were determined.

However, when the amount of carboxy group of sample (0) is (a0) μmol / g and the amount of carboxy group of sample (1) is (a1) μmol / g, the content of alkali metal salt of carboxy group (a2 ) Μmol / g was determined by the following formula.
(A2) = (a0) − (a1) [μmol / g]
[Measurement of non-Newtonian index]
It is a value calculated by measuring the shear rate and the shear stress under the conditions of 300 ° C. and L / D = 40 using a capilograph and using the following formula. The closer the N value is to 1, the closer the PPS has a linear structure, and the higher the N value, the more branched the structure.

［ただし、ＳＲは剪断速度（秒^−１）、ＳＳは剪断応力（ダイン／ｃｍ^２）、そしてＫは定数を示す。］

[Wherein SR represents a shear rate (second ⁻¹ ), SS represents a shear stress (dyne / cm ² ), and K represents a constant. ]

[Measuring method of melt viscosity V6]
Using a flow tester (CFT-500C type) manufactured by Shimadzu Corporation, an orifice having a temperature / 300 ° C., shear rate 10 sec ⁻¹ load 1.96 MPa, orifice length / diameter diameter ratio of the former / the latter of 10/1 Was measured after holding for 6 minutes.

[Melting point]
Using a differential scanning calorimeter (“PYRIS Diamond DSC” manufactured by Perkin Elmer), the temperature showing the maximum endothermic peak based on the analytical method (DSC method; conforming to JIS K-7121) using a differential scanning calorimeter was measured as the melting point.

Example 1
[Step 1]
In a 150 liter autoclave with a stirring blade to which a pressure gauge, a thermometer, a condenser, a decanter, and a rectifying column are connected, p-dichlorobenzene (hereinafter abbreviated as “p-DCB”) 33.222 kg (226 mol), NMP4 .560 kg (46 mol), 47.300 kg of a 47.33% by mass NaSH aqueous solution (230 mol as NaSH), and 18.533 g of a 49.21% by mass NaOH aqueous solution (228 mol as NaOH) were charged in a nitrogen atmosphere while stirring. The temperature was raised to 173 ° C. over 5 hours to distill 26.794 kg of water, and the autoclave was sealed. The p-DCB distilled azeotropically during dehydration was separated with a decanter and returned to the autoclave as needed. In the autoclave after the completion of the dehydration, the finely divided anhydrous sodium sulfide composition was dispersed in p-DCB. The NMP content in this composition was 0.089 kg (0.9 mol), indicating that 98% (45.1 mol) of the charged NMP was hydrolyzed to SMAB. The amount of SMAB in the autoclave was 0.196 mole per mole of sulfur atoms present in the autoclave. When the total amount of NaSH and NaOH charged is changed to anhydrous Na ₂ S, the theoretical dehydration amount is 27.921 g, so 812 g (45.1 mol) of the remaining water amount in the autoclave is 1127 g (62.6 mol). Is consumed in the hydrolysis reaction of NMP and NaOH and is not present in the autoclave as water, and the remaining 315 g (17.5 mol) remains in the autoclave in the form of water or crystal water. Show. The amount of water in the autoclave was 0.076 mol per mol of sulfur atoms present in the autoclave.

[Step 2]
After completion of the dehydration step, the internal temperature was cooled to 160 ° C., 45.203 kg (456 mol) of NMP was charged, and the temperature was raised to 185 ° C. The amount of water in the autoclave was 0.038 mol per 1 mol of NMP charged in step 2. When the gauge pressure reached 0.00 MPa, the valve connected to the rectifying column was opened, and the temperature was raised to an internal temperature of 200 ° C. over 1 hour. At this time, the cooling and the valve opening were controlled so that the rectification tower outlet temperature was 110 ° C. or lower. The distilled vapor of p-DCB and water was condensed by a condenser and separated by a decanter, and p-DCB was returned to the autoclave. The amount of distilled water was 273 g (15.2 mol).

[Step 3]
The water content in the autoclave at the start of Step 3 was 42 g (2.3 mol), 0.005 mol per mol of NMP charged in Step 2, and 0.010 mol per mol of sulfur atoms present in the autoclave. . The amount of SMAB in the autoclave was 0.196 mol per mol of sulfur atoms present in the autoclave, as in Step 1. Next, the temperature was raised from an internal temperature of 200 ° C. to 230 ° C. over 3 hours, stirred at 230 ° C. for 3 hours, then heated to 250 ° C. and stirred for 1 hour. The gauge pressure at an internal temperature of 200 ° C. was 0.03 MPa, and the final gauge pressure was 0.50 MPa. After cooling, 650 g of the obtained slurry was poured into 3 liters of water, stirred at 80 ° C. for 1 hour, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated 4 times. The cake was again adjusted to pH 4.0 by adding 3 liters of warm water and acetic acid, stirred for 1 hour, washed, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated twice. It dried at 120 degreeC overnight using the hot air dryer, and obtained 151 g of white powdery PPS resin (P-1). The melt viscosity at 300 ° C. of this polymer was about 1,200 poise. The non-Newton index was 0.99. The carboxy group content was 44 μmol / g, and the alkali metal salt was 9.6 μmol / g.

(Example 2)
[Step 1]
In a 150 liter autoclave with a stirring blade connected with a pressure gauge, a thermometer, a condenser, a decanter and a rectifying column, 33.222 kg (226 mol) of p-dichlorobenzene (hereinafter abbreviated as “p-DCB”), NMP3. 420 kg (34.5 mol), 47.33% by weight NaSH aqueous solution 27.300 kg (230 mol as NaSH), and 49.21 wt% NaOH aqueous solution 18.533 g (228 mol as NaOH) were charged and stirred under a nitrogen atmosphere Then, the temperature was raised to 173 ° C. over 5 hours to distill 27.300 kg of water, and then the autoclave was sealed. The p-DCB distilled azeotropically during dehydration was separated with a decanter and returned to the autoclave as needed. In the autoclave after the completion of the dehydration, the finely divided anhydrous sodium sulfide composition was dispersed in p-DCB. Since the NMP content in this composition was 0.079 kg (0.8 mol), 98 mol% (33.7 mol) of the charged NMP was NMP ring-opened (4- (methylamino)). It was shown to be hydrolyzed to the sodium salt of butyric acid (hereinafter abbreviated as “SMAB”). The amount of SMAB in the autoclave was 0.147 mol per mol of sulfur atoms present in the autoclave. When the total amount of NaSH and NaOH charged is changed to anhydrous Na ₂ S, the theoretical dehydration amount is 27.921 g, so 609 g (33.8 mol) of the remaining water amount in the autoclave is 878 g (48.8 mol). Is consumed in the hydrolysis reaction of NMP and NaOH and does not exist in the autoclave as water, and the remaining 269 g (14.9 mol) remains in the autoclave in the form of water or crystal water. Was showing. The amount of water in the autoclave was 0.065 mol per mol of sulfur atoms present in the autoclave.

[Step 2]
After the dehydration step, the internal temperature was cooled to 160 ° C., NMP46.343 kg (467.5 mol) was charged, and the temperature was raised to 185 ° C. The amount of water in the autoclave was 0.025 mol per 1 mol of NMP charged in step 2. When the gauge pressure reached 0.00 MPa, the valve connected to the rectifying column was opened, and the temperature was raised to an internal temperature of 200 ° C. over 1 hour. At this time, the cooling and the valve opening were controlled so that the rectification tower outlet temperature was 110 ° C. or lower. The distilled vapor of p-DCB and water was condensed by a condenser and separated by a decanter, and p-DCB was returned to the autoclave. The amount of distilled water was 228 g (12.7 mol).

[Step 3]
The water content in the autoclave at the start of Step 3 was 41 g (2.3 mol), 0.005 mol per 1 mol of NMP charged in Step 2, and 0.010 mol per 1 mol of sulfur atoms present in the autoclave. . The amount of SMAB in the autoclave was 0.147 mol per mol of sulfur atoms present in the autoclave, as in Step 1. Next, the temperature was raised from an internal temperature of 200 ° C. to 230 ° C. over 3 hours, stirred at 230 ° C. for 3 hours, then heated to 250 ° C. and stirred for 1 hour. The gauge pressure at an internal temperature of 200 ° C. was 0.03 MPa, and the final gauge pressure was 0.40 MPa. After cooling, 650 g of the obtained slurry was poured into 3 liters of water, stirred at 80 ° C. for 1 hour, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated 4 times. The cake was again adjusted to pH 4.0 by adding 3 liters of warm water and acetic acid, stirred for 1 hour, washed, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated twice. It dried at 120 degreeC overnight using the hot air dryer, and obtained 151 g of white powdery PPS resin (P-2). The melt viscosity of this polymer at 300 ° C. was about 1,800 poise. The non-Newton index was 1.02. The carboxy group content was 38 μmol / g, and the alkali metal salt was 4.8 μmol / g.

(Example 3)
[Step 1]
In a 150 liter autoclave with a stirring blade to which a pressure gauge, a thermometer, a condenser, a decanter, and a rectifying column are connected, p-dichlorobenzene (hereinafter abbreviated as “p-DCB”) 33.222 kg (226 mol), NMP2. 280 kg (23 mol), 47.33% by weight NaSH aqueous solution 27.300 kg (230 mol as NaSH), and 49.21 wt% NaOH aqueous solution 18.533 g (228 mol as NaOH) were charged under a nitrogen atmosphere with stirring. The temperature was raised to 173 ° C. over 5 hours to distill 27.300 kg of water, and then the autoclave was sealed. The p-DCB distilled azeotropically during dehydration was separated with a decanter and returned to the autoclave as needed. In the autoclave after the completion of the dehydration, the finely divided anhydrous sodium sulfide composition was dispersed in p-DCB. Since the NMP content in this composition was 0.069 kg (0.7 mol), 97 mol% (22.3 mol) of the charged NMP was a ring-opened product of NMP (4- (methylamino) It was shown to be hydrolyzed to the sodium salt of butyric acid (hereinafter abbreviated as “SMAB”). The amount of SMAB in the autoclave was 0.097 mol per mol of sulfur atoms present in the autoclave. When the total amount of NaSH and NaOH charged is changed to anhydrous Na ₂ S, the theoretical dehydration amount is 27.921 kg, so 401 g (22.3 mol) out of the remaining water amount 621 g (34.5 mol) in the autoclave. Is consumed in the hydrolysis reaction of NMP and NaOH and does not exist in the autoclave as water, and the remaining 220 g (12.2 mol) remains in the autoclave in the form of water or crystal water. Was showing. The amount of water in the autoclave was 0.053 mol per mol of sulfur atoms present in the autoclave.

[Step 2]
After completion of the dehydration step, the internal temperature was cooled to 160 ° C., NMP 47.492 kg (479 mol) was charged, and the temperature was raised to 185 ° C. The amount of water in the autoclave was 0.025 mol per 1 mol of NMP charged in step 2. When the gauge pressure reached 0.00 MPa, the valve connected to the rectifying column was opened, and the temperature was raised to an internal temperature of 200 ° C. over 1 hour. At this time, the cooling and the valve opening were controlled so that the rectification tower outlet temperature was 110 ° C. or lower. The distilled vapor of p-DCB and water was condensed by a condenser and separated by a decanter, and p-DCB was returned to the autoclave. The amount of distilled water was 179 g (9.9 mol).

[Step 3]
The water content in the autoclave at the start of Step 3 was 41 g (2.3 mol), 0.005 mol per 1 mol of NMP charged in Step 2, and 0.010 mol per 1 mol of sulfur atoms present in the autoclave. . The amount of SMAB in the autoclave was 0.097 mol per mol of sulfur atoms present in the autoclave, as in Step 1. Next, the temperature was raised from an internal temperature of 200 ° C. to 230 ° C. over 3 hours, stirred at 230 ° C. for 3 hours, then heated to 250 ° C. and stirred for 1 hour. The gauge pressure at an internal temperature of 200 ° C. was 0.03 MPa, and the final gauge pressure was 0.30 MPa. After cooling, 650 g of the obtained slurry was poured into 3 liters of water, stirred at 80 ° C. for 1 hour, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated 4 times. The cake was again adjusted to pH 4.0 by adding 3 liters of warm water and acetic acid, stirred for 1 hour, washed, and then filtered. The cake was again stirred with 3 liters of warm water for 1 hour, washed and filtered. This operation was repeated twice. It dried at 120 degreeC overnight using the hot air dryer, and obtained 151 g of white powdery PPS resin (P-3). The melt viscosity of this polymer at 300 ° C. was about 2,100 poise. The non-Newton index was 1.01. The content of carboxy group was 31 μmol / g, and the alkali metal salt was 3.0 μmol / g.

(Comparative Example 1)
In an autoclave, sodium sulfide 3.20 Kg (25 mol, containing 40% crystal water), sodium hydroxide 4 g, sodium acetate trihydrate 1.36 Kg (about 10 mol) and N-methyl-2-pyrrolidone (hereinafter referred to as NMP) Abbreviated to 7.9 kg), and gradually heated to 205 ° C. with stirring to remove about 1.5 liters of distilled water containing 1.36 kg of water.

To the residual mixture, 3.75 Kg (25.5 mol) of 1,4-dichlorobenzene and 2 Kg of NMP were added and heated at 265 ° C. for 3 hours. The reaction product was washed 5 times with warm water at 70 ° C. and dried under reduced pressure at 80 ° C. for 24 hours to obtain about 2 kg of powdered PPS resin having a melt viscosity of about 1,700 poise (300 ° C., shear rate 10 sec ⁻¹ ). It was. About 2 kg of the obtained powdery PPS resin was put into 20 liters of an aqueous acetic acid solution of pH 4 heated to 90 ° C., and stirred for about 30 minutes, followed by filtration, and about the time until the pH of the filtrate reached 7. This was washed with deionized water at 90 ° C. and dried under reduced pressure at 120 ° C. for 24 hours to obtain a powdered PPS resin (P-4). The carboxy group content of the resin was 50 μmol / g.

Examples 4 to 8 and Comparative Examples 3 to 5 [Method for producing pellets of PAS resin composition]
After 100 parts by mass of the polyarylene sulfide resin is mixed with 0.4 parts by mass of the silane coupling agent and the polyolefin described in Tables 1 to 3, the mixture is introduced into a twin screw extruder, and from the side feeder. While supplying glass fibers (glass fiber chopped strands having a fiber diameter of 10 μm and a length of 3 mm) at a ratio of 20 parts by mass with respect to 100 parts by mass of the polyarylene sulfide resin composition, A pellet of an arylene sulfide resin composition was obtained.

Next, various tests were performed using the pellets of the polyarylene sulfide resin composition.
[Melt viscosity]
The resin composition pellets were put into a melt indexer having a cylinder temperature of 330 ° C. and an orifice system of 1 mm, a load of 10 kg was applied, and the melt flow rate was measured after preheating for 5 minutes.

[Drawdown resistance / extrusion stability]
Using the melt viscosity as an index of drawdown resistance and extrusion stability at the time of blow molding, 3 to 10 g / 10 min is “good” (good with drawdown resistance and extrusion stability), 3 g / 10 Those with less than 5 minutes were evaluated as “bad” (extrusion stability was poor), and those over 20 g / 10 minutes were evaluated as “bad” (with poor drawdown resistance).

[Uniformity]
The resin composition pellets are supplied to a blow molding machine equipped with a 45 mmφ extruder, extruded at a cylinder temperature of 290 ° C. to form a parison having an outer diameter of 30 mm and a wall thickness of 4 mm, and then air is blown into the mold. A cylindrical container having a height of 250 mm, an outer diameter of 50 mm, and a wall thickness of about 2 to 3 mm was formed. The thickness of each of five arbitrary places of the upper part (30 mm from the upper end) and the lower part (30 mm from the lower end) of this molded article body was measured, and the uniformity was determined according to the following criteria.
The difference between the upper average thickness and the lower average thickness is within 0.2mm.
"○" if the difference in thickness is more than 0.2 and within 0.5mm
"△" if the difference in thickness is more than 0.5mm and within 1.0mm
“X” means that the difference in thickness exceeds 1.0 mm.

[Cold and thermal shock resistance]
Create a molded product with a metal (S55C) block wrapped in a 1 mm thick resin layer, and conduct a thermal cycle test of “1 cycle; −40 ° C./30 minutes to 140 ° C./30 minutes” in the gas phase And it evaluated by the cycle number which a crack generate | occur | produces in a PPS outer layer.

The determination was made according to the following criteria.
Peeling occurs in less than 10 cycles ... Rank "IV"
Peeling occurs at 10 to less than 50 cycles ... Rank "III"
Cracks occur at 50 or more and less than 100 cycles ... Rank "II"
More than 100 cycles ... Rank "I"

[Shock resistance]
The impact resistance was measured using a dumbbell specimen for a tensile test. Supply resin composition pellets to an injection molding machine, mold dumbbell specimens for tensile testing at a cylinder temperature of 300 ° C and a mold temperature of 140 ° C, and cut out the central part into a rod with a length of 80 mm, a width of 10 mm, and a thickness of 4 mm The test piece was used as a test piece, and a Charpy impact test was performed to measure the impact strength (kJ / mm ² ).

[Heat-resistant]
The test piece was heated in an oven at 240 ° C. for 3000 hours, the tensile strength after removal was measured, and the decrease from the tensile strength of the unheated test piece was expressed as a retention rate (%). Those having a retention rate exceeding 60% were determined to have good heat resistance, and those having 60% or less were determined to have poor heat resistance.

PO-1: Epoxy group-containing polyolefin (Sumitomo Chemical Co., Ltd. “Bond First 7L” ethylene 60 wt% -glycidyl methacrylate 3 wt% -methyl acrylate 27 wt% copolymer) Epoxy equivalent 5000 [eq / g]
PO-2: Unmodified polyolefin (“Tuffmer A4085” ethylene-butene copolymer manufactured by Mitsui Chemicals, Inc.)

Si-1; γ-glycidoxypropyltrimethoxysilane (Nippon Unicar “A187”)
Si-2; 2- (3,4 Epoxycyclohexyl) trimethoxysilane (“A1100” manufactured by Nihon Unicar)
Si-3; N-2 (aminoethyl) 3-aminopropyltriethoxysilane (“A1120” manufactured by Nihon Unicar)
Si-4; 3-isocyanatopropyltriethoxysilane (“A1310” manufactured by Nihon Unicar)

Claims (8)

It has a carboxyl group at the end at a rate of 25 to 45 [μmol / g], a non-Newtonian index of 0.90 to 1.15, and using a flow tester, temperature 300 ° C., load 1.96 MPa, orifice Polyarylene sulfide resin (A) having a melt viscosity in the range of 1,000 poise to 3,000 poise measured after holding for 6 minutes using an orifice having a length / orifice diameter ratio of 10/1 When, an epoxy equivalent of 3,000 to 20,000 [g / eq] epoxy group-containing polyolefin in the range of (B), the polyarylene sulfide fit de resin (a) the polyolefin with respect to 100 parts by weight ( B) melt kneading at a ratio of 13 to 30 parts by mass ;
The polyolefin (B) is a mixture of a polyolefin (B ′) having an epoxy group and a polyolefin (B ″) having no functional group that reacts with a carboxy group,
The manufacturing method of the resin composition characterized by these.   Melt flow rate value of the resin composition (measured value after preheating for 5 minutes) with a resin composition pellet charged into a melt indexer with a cylinder temperature of 330 ° C. and an orifice diameter of 1 mm and a load of 10 kg) The method for producing a resin composition according to claim 1, which is / 10 minutes.   2. The resin composition according to claim 1, wherein the polyarylene sulfide resin (A) is a polyarylene sulfide resin having an alkali metal salt of a carboxy group in a ratio of 2 to 20 [μmol / g] in the resin. Production method. In the presence of a solid alkali metal sulfide and an aprotic polar organic solvent, the polyhaloaromatic compound (a), the alkali metal hydrosulfide (b) and the organic acid alkali metal salt (c) are converted into the solid alkali metal. The organic acid alkali metal salt (c) is used in a ratio of 0.01 mol to less than 0.9 mol with respect to 1 mol in total of the sulfide and the alkali metal hydrosulfide (b), and is present in the reaction system. A crude polyarylene sulfide resin is produced by reacting under a condition that the amount of water is 0.02 mol or less with respect to 1 mol of the aprotic polar organic solvent, and then deionizing, It has a carboxy group at a terminal ratio of 25 to 45 [μmol / g], a non-Newtonian index of 0.90 to 1.15, and using a flow tester, a temperature of 300 ° C., a load of 1.96 MP. A polyarylene sulfide resin (A) having a melt viscosity in the range of 1,000 poise to 3,000 poise measured after being held for 6 minutes using an orifice having an orifice length / orifice diameter ratio of 10/1 Then, the resulting polyarylene sulfide resin (A ) is melt kneaded with an epoxy group-containing polyolefin ( B) having an epoxy equivalent in the range of 3,000 to 20,000 [g / eq]. The method for producing a resin composition according to claim 1. In addition to the polyarylene sulfide resin (A) and the polyolefin ( B), the proportion of the filler is 0.1 to 50 parts by mass with respect to 100 parts by mass of the polyarylene sulfide (A). The method for producing a resin composition according to claim 1, wherein the resin composition is melt kneaded. In addition to the polyarylene sulfide resin (A) and the polyolefin ( B) , a silane coupling agent is added to the polyarylene sulfide resin (A) in an amount of 0.01 to 1. The method for producing a resin composition according to claim 1, wherein the mixture is melt kneaded at a ratio of 0 part by mass.   A method for producing a molded product, comprising: obtaining a resin composition by the production method according to any one of claims 1 to 6; and molding the obtained resin composition.   The method for producing a molded product according to claim 7, wherein the molding is blow hollow molding.