WO2015129487A1 - ポリアリーレンスルフィド樹脂粉粒体組成物およびその製造方法 - Google Patents
ポリアリーレンスルフィド樹脂粉粒体組成物およびその製造方法 Download PDFInfo
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- WO2015129487A1 WO2015129487A1 PCT/JP2015/053971 JP2015053971W WO2015129487A1 WO 2015129487 A1 WO2015129487 A1 WO 2015129487A1 JP 2015053971 W JP2015053971 W JP 2015053971W WO 2015129487 A1 WO2015129487 A1 WO 2015129487A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
- C08L81/02—Polythioethers; Polythioether-ethers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/12—Making granules characterised by structure or composition
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/16—Solid spheres
- C08K7/18—Solid spheres inorganic
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D181/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur, with or without nitrogen, oxygen, or carbon only; Coating compositions based on polysulfones; Coating compositions based on derivatives of such polymers
- C09D181/04—Polysulfides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/12—Making granules characterised by structure or composition
- B29B2009/125—Micropellets, microgranules, microparticles
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2381/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2381/04—Polysulfides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/011—Nanostructured additives
Definitions
- the present invention relates to a polyarylene sulfide resin particle composition having a small average particle diameter, excellent powder flowability and low compressibility.
- Polyarylene sulfide typified by polyphenylene sulfide (hereinafter sometimes abbreviated as PPS) has excellent heat resistance, barrier properties, chemical resistance, electrical insulation properties, moisture and heat resistance, etc. It has suitable properties as an engineering plastic, and is used for various electric / electronic parts, mechanical parts, automobile parts, films, fibers, etc. mainly in injection molding and extrusion molding applications.
- PAS resin granules As various molding processes, coating agents, and heat-resistant additives, and the following methods have been proposed for producing PAS resin granules. ing.
- Patent Document 1 PPS is used as an island and another thermoplastic polymer is melt-kneaded as a sea to form a resin composition having a sea-island structure, and then the sea phase is dissolved and washed to obtain PPS resin particles.
- Patent Document 2 PPS resin particles are obtained by dissolving PPS in a high-temperature solvent and cooling and precipitating.
- Patent Document 3 it is difficult to eliminate the deterioration of fluidity due to compression in the lower part of the silo or hopper.
- the PAS resin powder Since the PAS resin powder is easily insulated due to static electricity due to its high electrical insulation, it is not excellent in fluidity. Therefore, there is a problem that troubles during supply and discharge in silos and the like frequently occur in the manufacturing process.
- the PAS resin granular material has a high degree of compression, and is compressed by powder pressure at the lower part of the silo or hopper, increasing the bulk density and causing further decrease in fluidity.
- the PPS resin powder obtained by the methods of Patent Documents 1 and 2 has a small particle size, the area in contact with neighboring particles is large, and the particles are likely to aggregate due to static electricity and have poor fluidity.
- the present invention has been achieved as a result of studying as an object to efficiently obtain a polyarylene sulfide resin granular material having a small average particle diameter, excellent powder flowability and low compressibility.
- the present invention has resulted in the following invention as a result of intensive studies to solve such problems.
- the present invention is as follows.
- An inorganic fine particle having an average particle size of 20 nm or more and 500 nm or less is added in an amount of 0.1 to 5 to 100 parts by weight of a polyarylene sulfide resin particle having an average particle size of more than 1 ⁇ m and 100 ⁇ m or less and a uniformity of 4 or less.
- a polyarylene sulfide resin granular composition containing parts by weight.
- Polyarylene sulfide resin granules having an average particle size of more than 1 ⁇ m and not more than 100 ⁇ m and a uniformity of 4 or less, obtained by pulverizing polyarylene sulfide resin particles having an average particle size of 40 ⁇ m or more and 2 mm or less The method for producing a polyarylene sulfide resin granular material composition according to any one of (1) to (3), wherein inorganic fine particles are blended in the composition.
- PAS resin The PAS in the present invention is a homopolymer or copolymer having a repeating unit of the formula, — (Ar—S) —, as the main structural unit, and preferably containing 80 mol% or more of the repeating unit.
- Ar is a group containing an aromatic ring in which a bond is present in the aromatic ring, and examples thereof include divalent repeating units represented by the following formulas (A) to (L), among which the formula ( The repeating unit represented by A) is particularly preferred.
- R1 and R2 are substituents selected from hydrogen, an alkyl group having 1 to 6 carbon atoms, an alkoxy group having 1 to 6 carbon atoms and a halogen group, and R1 and R2 are the same or different. May be.
- the PAS in the present invention may be any of a random copolymer, a block copolymer and a mixture thereof containing the above repeating unit.
- PASs include polyphenylene sulfide, polyphenylene sulfide sulfone, polyphenylene sulfide ketone, random copolymers thereof, block copolymers, and mixtures thereof.
- Particularly preferred PASs include polyphenylene sulfide, polyphenylene sulfide sulfone and polyphenylene sulfide ketone containing 80 mol% or more, particularly 90 mol% or more of p-phenylene sulfide units as the main structural unit of the polymer.
- the PAS used in the present invention can be obtained by various methods, for example, a method for obtaining a polymer having a relatively small molecular weight described in JP-B-45-3368, or JP-B-52-12240 and JP-A-61-7332. Can be produced by a method for obtaining a polymer having a relatively large molecular weight as described in Japanese Patent Publication No. JP-A.
- the obtained PPS resin is subjected to crosslinking / polymerization by heating in air, heat treatment under an inert gas atmosphere such as nitrogen or reduced pressure, washing with an organic solvent, hot water, an acid aqueous solution, etc., acid anhydride It can also be used after various treatments such as activation with functional group-containing compounds such as products, amines, isocyanates and functional group disulfide compounds.
- the PAS resin particles used in the present invention are not particularly limited, and the polymer obtained by the above-described method can be used as PAS resin particles, or the PAS resin is molded into pellets, fibers, or films. PAS resin particles can also be obtained.
- the PAS resin particles indicate a PAS resin having a particle size range suitable for the present invention and a PAS resin having a particle size larger than the particle size range suitable for the present invention.
- pulverization process mentioned later can be performed according to the form of the PAS resin particle to be used.
- the method of spray drying after dissolving the raw materials in the solvent the poor solvent precipitation method in which an emulsion is formed in the solvent and then contacting with the poor solvent, and the liquid for removing the organic solvent by drying after forming the emulsion in the solvent
- examples thereof include an intermediate drying method and a forced melt kneading method in which a sea-island structure is formed by mechanically kneading a resin component desired to be granulated and a resin component different from the resin component, and then removing the sea component with a solvent.
- a powder suitable for the present invention can be obtained by subjecting PAS resin particles having a large average particle diameter and PAS resin particles having a large degree of uniformity (not uniform) as raw materials.
- pulverization method there is no particular limitation on the pulverization method, and examples include jet mill, bead mill, hammer mill, ball mill, sand mill, turbo mill, and freeze pulverization.
- dry pulverization such as turbo mill, jet mill, and freeze pulverization is used.
- the average particle size of the PAS resin particles before pulverization is not particularly limited, but the PAS resin particles produced by a technique used in a general production method have an average particle size of about 40 ⁇ m to 10 mm.
- the particle size before pulverization is large, the time required for pulverization becomes long, so it is preferable to use PAS resin particles of 40 ⁇ m or more and 2 mm or less as a raw material.
- a PAS resin granule having an average particle size of more than 1 ⁇ m and 100 ⁇ m or less is used by performing a pulverization treatment as necessary.
- the lower limit of the average particle size of the PAS resin particles is preferably 3 ⁇ m, more preferably 5 ⁇ m, still more preferably 8 ⁇ m, particularly preferably 10 ⁇ m, particularly preferably 13 ⁇ m, and most preferably 15 ⁇ m. is there.
- the upper limit of the average particle diameter is preferably 75 ⁇ m, more preferably 70 ⁇ m, still more preferably 65 ⁇ m, particularly preferably 60 ⁇ m, particularly preferably 55 ⁇ m, and most preferably 50 ⁇ m.
- the PAS resin produced by a general production method has a wide particle size distribution and a high degree of uniformity of 5 or more, but the particle size distribution can be made uniform by performing a pulverization treatment. Since the granular material having a small degree of uniformity has a low compressibility when the powder pressure is applied, the uniformity of the PAS resin granular material of the present invention is 4 or less.
- the uniformity of the PAS resin particles is preferably 3.2 or less, more preferably 3.0 or less, still more preferably 3 or less, particularly preferably 2.5 or less, and extremely preferably 2 or less.
- the lower limit of the uniformity is theoretically 1, it is preferably 1.1 or more in practice, more preferably 1.15 or more, still more preferably 1.2 or more, and particularly preferably 1 .3 or more, and particularly preferably 1.4 or more.
- the uniformity of the PAS resin granular material exceeds 4, even if the average particle size is in an appropriate range, the degree of compression is large and the effects of the present invention cannot be achieved.
- the average particle size of the PAS resin particles or PAS resin particles is from the small particle size side of the particle size distribution measured by a laser diffraction particle size distribution analyzer based on Mie's scattering / diffraction theory.
- the particle size (d50) is such that the cumulative frequency is 50%.
- the uniformity of the PAS resin granular material in the present invention is the cumulative frequency from the small particle size side to the particle size (d60) at which the cumulative frequency from the small particle size side of the particle size distribution measured by the above method is 60%. Is the value divided by the particle size (d10) at 10%.
- inorganic fine particles In the present invention, it is important to add inorganic fine particles in order to improve the fluidity of the polyarylene sulfide resin granules.
- the fluidity of PAS resin granules deteriorates due to the interaction with nearby particles when the particle size is small, but the interparticle distance is increased by adding inorganic fine particles having a particle size smaller than that of the PAS resin granules. , Fluidity can be improved.
- the inorganic fine particles to be added to the PAS resin particles are those having an average particle size of 20 nm to 500 nm.
- an average particle diameter is the value measured by the method similar to the average particle diameter of said PAS resin particle or PAS resin granular material.
- the upper limit of the average particle size of the inorganic fine particles is preferably 400 nm, more preferably 300 nm, more preferably 200 nm, particularly preferably 150 nm, and particularly preferably 100 nm.
- the lower limit is preferably 20 nm, more preferably 30 nm, more preferably 40 nm, and particularly preferably 50 nm.
- the average particle diameter of the inorganic fine particles exceeds 500 nm, the effect of improving the fluidity of the PAS resin powder composition is not sufficient.
- the average particle diameter of inorganic fine particles is less than 20 nm, an effect of improving fluidity is obtained, but an effect of reducing the degree of compression of the PAS resin particle composition is difficult to obtain.
- calcium carbonate powder such as light calcium carbonate, heavy calcium carbonate, finely divided calcium carbonate, special calcium-based filler; Sintered fine powder, montmorillonite, bentonite, etc., clay such as silane modified clay (aluminum silicate powder); talc; fused silica, crystalline silica, amorphous silica and other silica (silicon dioxide) powder; diatomaceous earth, Silica-containing compounds such as silica sand; natural minerals such as pumice powder, pumice balloon, slate powder, and mica powder; alumina-containing compounds such as alumina (aluminum oxide), alumina colloid (alumina sol), alumina white, and aluminum sulfate Barium sulfate, lithopone, calcium sulfate, disulfur Minerals such as molybdenum and graphite; glass-based fillers such as glass fibers, glass
- Silica powder is particularly preferable, and among them, amorphous silica powder that is less harmful to the human body is extremely preferable industrially.
- the shape of the inorganic fine particles in the present invention includes a spherical shape, a porous shape, a hollow shape, an indefinite shape, and the like, and is not particularly defined, but a spherical shape is preferable among them because it exhibits good fluidity.
- the spherical shape includes not only a true sphere but also a distorted sphere.
- the shape of the inorganic fine particles is evaluated by the circularity when the particles are projected two-dimensionally.
- the circularity is (peripheral length of a circle equal to the area of the projected particle image) / (peripheral length of the projected particle).
- the average circularity of the inorganic fine particles is preferably 0.7 or more and 1 or less, more preferably 0.8 or more and 1 or less, and still more preferably 0.9 or more and 1 or less.
- Silica powder is produced by combustion method silica obtained by burning a silane compound (ie, fumed silica), deflagration silica obtained by explosively burning metal silicon powder, sodium silicate and mineral acid.
- silica obtained by neutralization reaction (of which, synthesized and aggregated under alkaline conditions is precipitated silica, and synthesized and aggregated under acidic conditions is gel silica), dehydrated from sodium silicate with ion exchange resin Colloidal silica (silica sol) obtained by polymerizing acidic silicic acid obtained by sodium to alkalinity, and sol-gel silica obtained by hydrolysis of a silane compound can be broadly classified.
- sol-gel silica Is preferably sol-gel silica. That is, silica is preferable among the inorganic fine particles, more preferably sol-gel silica and / or spherical silica, and most preferably sol-gel spherical silica.
- the surface is hydrophobized with a silane compound or a silazane compound.
- a silane compound or a silazane compound By hydrophobizing the surface, aggregation of inorganic fine particles is suppressed, and dispersibility of the inorganic fine particles in the PAS resin powder is improved.
- silane compound examples include methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, n-propyltrimethoxysilane, n-propyltriethoxysilane, isopropyltrimethoxysilane, isopropyltriethoxysilane, Non-substituted or halogen-substituted trialkoxysilane such as butyltrimethoxysilane, butyltriethoxysilane, hexyltrimethoxysilane, trifluoropropyltrimethoxysilane, heptadecafluorodecyltrimethoxysilane, preferably methyltrimethoxysilane, Methyltriethoxysilane, ethyltrimethoxysilane and ethyltriethoxysilane, more
- silazane compound examples include hexamethyldisilazane and hexaethyldisilazane, preferably hexamethyldisilazane.
- monofunctional silane compounds include monosilanol compounds such as trimethylsilanol and triethylsilanol; monochlorosilanes such as trimethylchlorosilane and triethylchlorosilane; monoalkoxysilanes such as trimethylmethoxysilane and trimethylethoxysilane; trimethylsilyldimethylamine and trimethylsilyldiethylamine And monoacyloxysilanes such as trimethylacetoxysilane, preferably trimethylsilanol, trimethylmethoxysilane or trimethylsilyldiethylamine, particularly preferably trimethylsilanol or trimethylmethoxysilane.
- These inorganic fine particles can be used alone or in combination of two or more.
- the compounding amount of the inorganic fine particles is 0.1 to 5 parts by weight with respect to 100 parts by weight of the PAS resin powder.
- the upper limit of the compounding material is preferably 4 parts by weight, more preferably 3 parts by weight, still more preferably 2 parts by weight, and particularly preferably 1 part by weight.
- 0.2 weight part is preferable, as for the minimum of a compounding quantity, 0.3 weight part is more preferable, and 0.4 weight part is further more preferable.
- inorganic fine particles are blended into the PAS resin powder.
- a method for obtaining a uniform resin powder composition is not particularly defined, and the resin powder and inorganic fine particles are mixed by a known method.
- a method of blending inorganic fine particles and simultaneously performing pulverization and mixing can also be employed.
- a mixing method As a mixing method, a mixing method by shaking, a mixing method involving pulverization such as a ball mill or a coffee mill, a mixing method using a stirring blade such as a Nauter mixer or a Henschel mixer, or a mixing method for rotating a container such as a V-type mixer.
- a method of drying after liquid phase mixing in a solvent, a mixing method of stirring by an air stream using a flash blender, a mixing method of spraying particles and / or slurry using an atomizer, etc. can be adopted. .
- PAS resin powder composition A PAS resin powder composition in which inorganic fine particles are blended with a PAS resin powder is characterized by excellent powder flowability and low compression. Specifically, the angle of repose is 40 degrees or less according to a preferred aspect of the invention, 38 degrees or less according to a more preferred aspect, 35 degrees or less according to a more preferred aspect, and / or the degree of compression. However, according to a preferred embodiment of the invention, it is 7.5 or less, according to a more preferred embodiment, it is 6.5 or less, and according to a more preferred embodiment, a PAS resin powder composition is obtained that is 5.5 or less. .
- the angle of repose and the degree of compression are values measured based on the measurement method of Carr's fluidity index (Non-patent Document 1).
- Such a granular material is excellent in fluidity and difficult to be compacted by powder pressure, so troubles such as clogging during supply / discharge to a silo and blockage during pneumatic transportation are unlikely to occur.
- the average particle size of the PAS resin granules was measured by using Nikkiso's laser diffraction / scattering particle size distribution analyzer MT3300EXII, and polyoxyethylene cumylphenyl ether (trade name: Nonal 912A, manufactured by Toho Chemical Co., Ltd., hereinafter referred to as Nonal 912A). ) was measured using a 0.5 mass% aqueous solution. Specifically, a cumulative curve is obtained by setting the total volume of fine particles obtained by analyzing laser scattered light by the microtrack method to 100%, and the particle size (median at which the cumulative curve from the small particle size side becomes 50% The diameter: d50) was defined as the average particle diameter of the PAS resin particles.
- the average particle size of fumed silica randomly select 100 particles from an image magnified 100,000 times using an electron microscope, and measure the particle size using the maximum length as the particle size. The number average value was defined as the average particle size.
- the average particle diameter of silica other than fumed silica was measured by the same method as that for PAS resin particles.
- the uniformity of the PAS resin particles was defined as the d60 / d10 value of the particle size distribution measured using a Nikkiso laser diffraction / scattering particle size distribution analyzer MT3300EXII. The wider the particle size distribution, the greater the uniformity.
- the obtained cake was dried at 120 ° C. under a nitrogen stream to obtain PAS-1.
- the obtained PAS-1 had an average particle size of 1600 ⁇ m and a uniformity of 4.1.
- the obtained cake was dried at 120 ° C. under a nitrogen stream to obtain PAS-2.
- the obtained PAS-2 had an average particle size of 40 ⁇ m and a uniformity of 5.0.
- PAS-1 was pulverized with a jet mill (100AFG manufactured by Hosokawa Micron Corporation) for 120 minutes to obtain a granular material having an average particle size of 40 ⁇ m and a uniformity of 1.6.
- a jet mill 100AFG manufactured by Hosokawa Micron Corporation
- the repose angle of the obtained granular material composition was 36 degrees, and the compression rate was 5.4%.
- Example 2 A PAS resin powder was obtained in the same manner as in Example 1 except that the weight of the added inorganic fine particles was 3.0 g. The repose angle of the obtained granular material composition was 31 degrees, and the compression rate was 5.3%.
- Example 3 A PAS resin powder was prepared in the same manner as in Example 1 except that the added inorganic fine particles were sol-gel spherical silica (X-24-9163A manufactured by Shin-Etsu Chemical Co., Ltd.) having an average particle diameter of 110 nm and surface-treated with hexamethyldisilazane. Granules were obtained. The repose angle of the obtained granular material composition was 35 degrees, and the compression rate was 5.5%.
- sol-gel spherical silica X-24-9163A manufactured by Shin-Etsu Chemical Co., Ltd.
- Example 1 A PAS resin powder was obtained in the same manner as in Example 1 except that the inorganic fine particles were not added.
- the repose angle of the obtained granular material composition was 41 degrees, and the compression rate was 19.3%.
- Example 2 A PAS resin powder was obtained in the same manner as in Example 1 except that the added inorganic fine particles were fumed silica (EVERIK AEROSIL 380) having an average particle diameter of 7 nm.
- the repose angle of the obtained granular material composition was 34 degrees, and the compression rate was 7.6%.
- PAS-2 was pulverized with a jet mill (100AFG manufactured by Hosokawa Micron Corporation) for 60 minutes to obtain a granular material having an average particle size of 15 ⁇ m and a uniformity of 3.2.
- a jet mill 100AFG manufactured by Hosokawa Micron Corporation
- the repose angle of the obtained granular composition was 39 degrees, and the compression rate was 7.2%.
- Example 5 A PAS resin powder was obtained in the same manner as in Example 4 except that the added inorganic fine particles were sol-gel spherical silica (X-24-9163A manufactured by Shin-Etsu Chemical Co., Ltd.) having an average particle diameter of 110 nm and surface-treated with hexamethyldisilazane. Granules were obtained. The repose angle of the obtained granular composition was 39 degrees, and the compression rate was 7.2%.
- sol-gel spherical silica X-24-9163A manufactured by Shin-Etsu Chemical Co., Ltd.
- Example 3 A PAS resin powder was obtained in the same manner as in Example 4 except that the added inorganic fine particle was fumed silica having an average particle diameter of 7 nm (AEROSIL 380 manufactured by Nippon Aerosil Co., Ltd.). The repose angle of the obtained granular material composition was 37 degrees, and the compression rate was 9.3%.
- AEROSIL 380 manufactured by Nippon Aerosil Co., Ltd.
- PAS-2 powder particles were obtained in the same manner as in Example 4 except that PAS-2 was not pulverized.
- the repose angle of the obtained granular composition was 47 degrees, and the compression rate was 16.1%.
- the polyarylene sulfide resin particles obtained by the present invention have excellent powder flowability and thus are excellent in handling properties and are suitably used as molding materials such as injection molding and extrusion molding. Furthermore, since the polyarylene sulfide resin particles obtained by the present invention have a fine particle size and good powder fluidity, good surface smoothness when used as powder coating matrix particles. And when used as a matrix resin of a carbon fiber reinforced resin, good impregnation can be obtained, so that it can be particularly preferably used.
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Abstract
Description
(1)平均粒径が1μmを超え100μm以下であり、均一度が4以下であるポリアリーレンスルフィド樹脂粉粒体100重量部に、平均粒径20nm以上500nm以下の無機微粒子を0.1~5重量部配合したポリアリーレンスルフィド樹脂粉粒体組成物。
(2)前記無機微粒子が球状シリカ微粒子であることを特徴とする(1)記載のポリアリーレンスルフィド樹脂粉粒体組成物。
(3)ポリアリーレンスルフィド樹脂粉粒体の平均粒径が10以上50μm以下である(1)または(2)記載のポリアリーレンスルフィド樹脂粉粒体組成物。
(4)平均粒径が40μm以上2mm以下のポリアリーレンスルフィド樹脂粒子を粉砕して得られる、平均粒径が1μmを超え100μm以下であり、均一度が4以下であるポリアリーレンスルフィド樹脂粉粒体に無機微粒子を配合することを特徴とする(1)~(3)のいずれか記載のポリアリーレンスルフィド樹脂粉粒体組成物の製造方法。
(5)粉砕が乾式粉砕であることを特徴とする(4)記載のポリアリーレンスルフィド樹脂粉粒体組成物の製造方法。
本発明におけるPASとは、式、-(Ar-S)-の繰り返し単位を主要構成単位とする、好ましくは当該繰り返し単位を80モル%以上含有するホモポリマーまたはコポリマーである。Arは結合手が芳香環に存在する芳香環を含む基であり、下記の式(A)~式(L)などで表される二価の繰り返し単位などが例示されるが、なかでも式(A)で表される繰り返し単位が特に好ましい。
また、本発明におけるPASは上記繰り返し単位を含むランダム共重合体、ブロック共重合体及びそれらの混合物のいずれかであってもよい。
本発明に使用するPAS樹脂粒子は、特に制限されるものではなく、上記手法で得られる重合体をPAS樹脂粒子とすることもできるし、PAS樹脂をペレットや繊維、フィルムに成型したものなどからPAS樹脂粒子を得ることも出来る。ここでPAS樹脂粒子とは、本発明に好適な粒径範囲のPAS樹脂および本発明に好適な粒径範囲よりも大きな粒径のPAS樹脂を示す。また、使用するPAS樹脂粒子の形態に応じて後述する粉砕処理を行うことができる。また、溶媒に原材料を溶解させた後にスプレードライする方法、溶媒中でエマルションを形成した後で貧溶媒に接触させる貧溶媒析出法、溶媒中でエマルションを形成した後で有機溶媒を乾燥除去する液中乾燥法、粒子化したい樹脂成分とそれとは異なる樹脂成分とを機械的に混練することにより海島構造を形成させ、その後に海成分を溶媒で除去する強制溶融混練法も挙げられる。
本発明においては、平均粒径が大きいPAS樹脂粒子や、均一度が大きい(均一でない)PAS樹脂粒子を原料として、粉砕処理を行うことで本発明に適する粉粒体を得ることが出来る。
本発明において、ポリアリーレンスルフィド樹脂粉粒体の流動性を改善するために無機微粒子を添加することが重要である。PAS樹脂粉粒体の流動性は、粒径が小さいと近傍の粒子との相互作用により悪化するが、PAS樹脂粉粒体よりも粒径の小さな無機微粒子を添加することで粒子間距離を広げ、流動性を改善することができる。
本発明における無機微粒子の形状は、球状、多孔状、中空状、不定形状などがあり特に定めるものではないが、良好な流動性を示すことから中でも球状であることが好ましい。
この場合、球状とは真球だけでなく、歪んだ球も含む。なお、無機微粒子の形状は、粒子を二次元に投影した時の円形度で評価する。ここで円形度とは、(投影した粒子像の面積と等しい円の周囲長)/(投影した粒子の周囲長)である。無機微粒子の平均円形度は、0.7以上1以下が好ましく、0.8以上1以下がより好ましい、さらに好ましくは0.9以上1以下が好ましい。
シリカ粉末は、その製法によって、シラン化合物を燃焼させて得られる燃焼法シリカ(即ち、フュームドシリカ)、金属珪素粉を爆発的に燃焼させて得られる爆燃法シリカ、珪酸ナトリウムと鉱酸との中和反応によって得られる湿式シリカ(このうち、アルカリ条件で合成し凝集させたものを沈降法シリカ、酸性条件で合成し凝集させたものをゲル法シリカという)、珪酸ナトリウムからイオン交換樹脂で脱ナトリウムして得られた酸性珪酸をアルカリ性にして重合することで得られるコロイダルシリカ(シリカゾル)、シラン化合物の加水分解によって得られるゾルゲル法シリカなどに大別できるが、本発明の効果を得るためには、ゾルゲル法シリカが好ましい。
すなわち、無機微粒子の中でもシリカが好ましく、さらに好ましくはゾルゲル法シリカおよび/または球状シリカ、なかでもゾルゲル法球状シリカが最も好ましい。
さらに好ましくはシラン化合物やシラザン化合物等で表面を疎水化処理したものが用いられる。表面を疎水化処理することにより、無機微粒子同士の凝集を抑制し、無機微粒子のPAS樹脂粉粒体への分散性が向上する。前記シラン化合物は、例えばメチルトリメトキシシラン、メチルトリエトキシシラン、エチルトリメトキシシラン、エチルトリエトキシシラン、n-プロピルトリメトキシシラン、n-プロピルトリエトキシシラン、イソプロピルトリメトキシシラン、イソプロピルトリエトキシシラン、ブチルトリメトキシシラン、ブチルトリエトキシシラン、ヘキシルトリメトキシシラン、トリフルオロプロピルトリメトキシシラン、ヘプタデカフルオロデシルトリメトキシシラン等の非置換若しくはハロゲン置換のトリアルコキシシラン等、好ましくは、メチルトリメトキシシラン、メチルトリエトキシシラン、エチルトリメトキシシラン及びエチルトリエトキシシラン、より好ましくは、メチルトリメトキシシラン及びメチルトリエトキシシラン、またはこれらの部分加水分解縮合生成物が挙げられる。また、前記シラザン化合物としては、例えば、ヘキサメチルジシラザン、ヘキサエチルジシラザン等、好ましくはヘキサメチルジシラザンが挙げられる。1官能性シラン化合物としては、例えば、トリメチルシラノール、トリエチルシラノール等のモノシラノール化合物;トリメチルクロロシラン、トリエチルクロロシラン等のモノクロロシラン;トリメチルメトキシシラン、トリメチルエトキシシラン等のモノアルコキシシラン;トリメチルシリルジメチルアミン、トリメチルシリルジエチルアミン等のモノアミノシラン;トリメチルアセトキシシラン等のモノアシルオキシシランが挙げられ、好ましくは、トリメチルシラノール、トリメチルメトキシシラン又はトリメチルシリルジエチルアミン、特に好ましくは、トリメチルシラノール又はトリメチルメトキシシランが挙げられる。
また、配合量の下限は、0.2重量部が好ましく、0.3重量部がより好ましく、0.4重量部がさらに好ましい。
本発明では、前記のPAS樹脂粉粒体に、無機微粒子を配合する。均一な樹脂粉粒体組成物とするための方法としては特に定めるものではなく、樹脂粉粒体と無機微粒子を公知の方法で混合する。前述した粉砕処理を行う際に、無機微粒子を配合して、粉砕と混合を同時に行う方法も採用できる。
PAS樹脂粉粒体に無機微粒子を配合したPAS樹脂粉粒体組成物は、粉体流動性に優れ、圧縮度が低い特徴を有する。具体的には、安息角が発明の好ましい様態によれば40度以下であり、より好ましい様態によれば38度以下であり、さらに好ましい様態によれば35度以下である、および/または圧縮度が発明の好ましい様態によれば7.5以下であり、より好ましい様態によれば6.5以下であり、さらに好ましい様態によれば5.5以下であるPAS樹脂粉粒体組成物が得られる。
PAS樹脂粉粒体の平均粒径は日機装製レーザー回折・散乱方式粒度分布測定装置MT3300EXIIを用い、分散媒としてポリオキシエチレンクミルフェニルエーテル(商品名ノナール912A 東邦化学工業製 以後、ノナール912Aと称す)の0.5質量%水溶液を用いて測定した。具体的にはマイクロトラック法によるレーザーの散乱光を解析して得られる微粒子の総体積を100%として累積カーブを求め、小粒径側からの累積カーブが50%となる点の粒径(メジアン径:d50)をPAS樹脂粉粒体の平均粒径とした。
PAS樹脂粉粒体の均一度は、日機装製レーザー回折・散乱方式粒度分布測定装置MT3300EXIIを用いて測定した粒径分布のd60/d10の値をPAS樹脂粉粒体の均一度とした。粒度分布が広いほど均一度は大きくなる。
PAS樹脂粉粒体またはPAS樹脂粉粒体組成物の安息角は、ホソカワミクロン製パウダーテスターPT-N型を用いて測定した。
PAS樹脂粉粒体またはPAS樹脂粉粒体組成物の圧縮度は、ホソカワミクロン製パウダーテスターPT-N型を用いて測定したゆるめ嵩密度と固め嵩密度から以下の式で算出した。
[製造例1]
撹拌機付きの1リットルオートクレーブに、47%水硫化ナトリウム1.00モル、46%水酸化ナトリウム1.05モル、N-メチル-2-ピロリドン(NMP)1.65モル、酢酸ナトリウム0.45モル、及びイオン交換水5.55モルを仕込み、常圧で窒素を通じながら225℃まで約2時間かけて徐々に加熱し、水11.70モルおよびNMP0.02モルを留出したのち、反応容器を160℃に冷却した。また、硫化水素の飛散量は0.01モルであった。
攪拌機付きの1リットルオートクレーブに、47%水硫化ナトリウム1.00モル、48%水酸化ナトリウム1.04モル、N-メチル-2-ピロリドン(NMP)2.12モル、及びイオン交換水5.55モルを仕込み、常圧で窒素を通じながら225℃まで約2時間かけて徐徐に加熱し、水11.70モルおよびNMP0.02モルを留出したのち、反応容器を160℃に冷却した。また、硫化水素の飛散量は0.01モルであった。
PAS-1をジェットミル(ホソカワミクロン製100AFG)で120分間粉砕し、平均粒径40μm、均一度1.6の粉粒体を得た。この粉粒体100gに対してヘキサメチルジシラザンで表面処理した平均粒径50nmのゾルゲル法球状シリカ(信越化学工業株式会社製X-24-9404)を0.5g添加し、振とうにより混合した。得られた粉粒体組成物の安息角は36度、圧縮率は5.4%であった。
添加した無機微粒子の重量が3.0gである以外は実施例1と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は31度、圧縮率は5.3%であった。
添加した無機微粒子がヘキサメチルジシラザンで表面処理した平均粒径110nmのゾルゲル法球状シリカ(信越化学工業株式会社製X-24-9163A)である以外は実施例1と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は35度、圧縮率は5.5%であった。
無機微粒子を添加しなかったこと以外は実施例1と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は41度、圧縮率は19.3%であった。
添加した無機微粒子が平均粒径7nmのフュームドシリカ(EVONIK製AEROSIL380)である以外は実施例1と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は34度、圧縮率は7.6%であった。
PAS-2をジェットミル(ホソカワミクロン製100AFG)で60分間粉砕し、平均粒径15μm、均一度3.2の粉粒体を得た。この粉粒体100gに対してヘキサメチルジシラザンで表面処理した平均粒径50nmのゾルゲル法球状シリカ(信越化学工業株式会社製X-24-9404)を0.5g添加し、振とうにより混合した。得られた粉粒体組成物の安息角は39度、圧縮率は7.2%であった。
添加した無機微粒子がヘキサメチルジシラザンで表面処理した平均粒径110nmのゾルゲル法球状シリカ(信越化学工業株式会社製X-24-9163A)である以外は実施例4と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は39度、圧縮率は7.2%であった。
添加した無機微粒子が平均粒径7nmのフュームドシリカ(日本アエロジル製AEROSIL380)である以外は実施例4と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は37度、圧縮率は9.3%であった。
PAS-2の粉砕を行わなかったことは実施例4と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は47度、圧縮率は16.1%であった。
無機微粒子を添加しなかったこと以外は比較例4と同様にして、PAS樹脂粉粒体を得た。得られた粉粒体組成物の安息角は48度、圧縮率は19.7%であった。
Claims (5)
- 平均粒径が1μmを超え100μm以下であり、均一度が4以下であるポリアリーレンスルフィド樹脂粉粒体100重量部に、平均粒径20nm以上500nm以下の無機微粒子を0.1~5重量部配合したポリアリーレンスルフィド樹脂粉粒体組成物。
- 前記無機微粒子が球状シリカ微粒子であることを特徴とする請求項1記載のポリアリーレンスルフィド樹脂粉粒体組成物。
- ポリアリーレンスルフィド樹脂粉粒体の平均粒径が10μm以上50μm以下である請求項1または2記載のポリアリーレンスルフィド樹脂粉粒体組成物。
- 請求項1~3のいずれか1項記載のポリアリーレンスルフィド樹脂粉粒体組成物の製造方法であって、平均粒径が40μm以上2mm以下のポリアリーレンスルフィド樹脂粒子を粉砕して得られる、平均粒径が1μmを超え100μm以下であり、均一度が4以下であるポリアリーレンスルフィド樹脂粉粒体に無機微粒子を配合することを特徴とするポリアリーレンスルフィド樹脂粉粒体組成物の製造方法。
- 粉砕が乾式粉砕であることを特徴とする請求項4記載のポリアリーレンスルフィド樹脂粉粒体組成物の製造方法。
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JPWO2017126484A1 (ja) * | 2016-01-20 | 2018-01-25 | 東レ株式会社 | ポリアリーレンスルフィド樹脂粉粒体およびその製造方法 |
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CN108368275A (zh) * | 2016-01-20 | 2018-08-03 | 东丽株式会社 | 聚芳撑硫醚树脂粉粒体及其制造方法 |
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JPWO2018074353A1 (ja) * | 2016-10-21 | 2019-08-22 | 東レ株式会社 | ポリアリーレンスルフィド樹脂粉粒体混合物および三次元造形物の製造方法 |
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WO2020022439A1 (ja) * | 2018-07-27 | 2020-01-30 | ポリプラスチックス株式会社 | 熱プレス成形品用複合材料及び熱プレス成形品 |
JPWO2020022439A1 (ja) * | 2018-07-27 | 2020-08-06 | ポリプラスチックス株式会社 | 熱プレス成形品用複合材料及び熱プレス成形品 |
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CN105612218A (zh) | 2016-05-25 |
CN105612218B (zh) | 2017-09-15 |
KR101754047B1 (ko) | 2017-07-04 |
KR20160126967A (ko) | 2016-11-02 |
JPWO2015129487A1 (ja) | 2017-03-30 |
ES2690450T3 (es) | 2018-11-21 |
EP3112424B1 (en) | 2018-08-15 |
MX2016011057A (es) | 2018-08-14 |
JP5839148B1 (ja) | 2016-01-06 |
CA2927426A1 (en) | 2015-09-03 |
US20160362524A1 (en) | 2016-12-15 |
CA2927426C (en) | 2021-06-22 |
EP3112424A4 (en) | 2017-07-12 |
EP3112424A1 (en) | 2017-01-04 |
US9862804B2 (en) | 2018-01-09 |
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