Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1999-09-29
2002-07-02
Szekely, Peter (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S265000, C524S412000, C524S414000, C524S437000
Reexamination Certificate
active
06414072
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field to which the Invention Belongs
The present invention relates to a flame-retardant thermoplastic resin composition obtained by blending (A) a thermoplastic resin which forms no anisotropic molten phase and (B) a liquid-crystal polymer capable of forming an anisotropic molten phase with (C) a halogen-containing organic compound and (D) a fluorine compound, and injection moldings thereof.
2. Prior Art
An alloy of a thermoplastic resin and a liquid-crystal polymer has been so far known for a material having excellent characteristics as a thin molding material, as described in JP-A 7-179743. This alloy is a material having both an inexpensiveness of the thermoplastic resin and mechanical properties and an easy moldability of the liquid-crystal polymer. Further, the greatest characteristics of this alloy are that the liquid-crystal polymer is readily fiberized through injection-molding to exhibit a much higher reinforcing effect than ever, and that the properties of the resulting moldings are therefore so specific that thin moldings excellent particularly in the mechanical strength can be provided. However, in the recent electric and electronic fields, the flame retardancy has been often required from necessity. In order to have a resin flame-retardant, it is considered that a combination of a usual flame retardant and a usual flame retardant aid is blended with it, like with a general thermoplastic resin. Nevertheless, in case of this alloy, there have been problems that, when an antimony compound or the like often used as a flame retardant aid is employed, a catalytic activity acts in imparting heat retentivity and a reaction arises between a thermoplastic resin and a liquid-crystal polymer, so that fibers of the liquid-crystal polymer to be inherently formed in a matrix phase of the thermoplastic resin in the injection-molding can not be formed, for which a thin moldability and a high rigidity, as one of the characteristics of this composition, are impaired.
DISCLOSURE OF THE INVENTION
Summary of the Invention
The present inventors have assiduously conducted investigations in view of the above-mentioned problems, and have consequently found that a thermoplastic resin composition, having an excellent stability of a heat retentivity imparted when injection-molding it, exhibiting an extremely high reinforcing effect which has been heretofore unattainable because the liquid-crystal polymer can be readily fiberized in moldings by injection-molding this, and also having an excellent flame retardancy, can be obtained by blending a resin component composed of (A) a thermoplastic resin and (B) a liquid-crystal polymer with (C) a halogen-containing organic compound and (D) a fluorine compound. This finding has led to completion of the present invention.
That is, an object of the present invention is a flame-retardant thermoplastic resin composition wherein 100 parts by weight of a resin component composed of 99 to 50 parts by weight of a thermoplastic resin (A) not forming an anisotropic molten phase and 1 to 50 parts by weight of a liquid-crystal polymer (B) capable of forming an anisotropic molten phase are blended with 1.0 to 20 parts by weight of a halogen-containing organic compound (C) and 0.01 to 10 parts by weight of a fluorine compound (D). Another object of the present invention is injection moldings obtained by injection-molding said flame-retardant thermoplastic resin composition, wherein the liquid-crystal polymer (B) is micro-dispersed in the form of fibers having an average aspect ratio of at least 6 in a matrix phase of the thermoplastic resin (A).
Detailed Description of the Invention
Hereinafter, the constitution of the present invention will be described in detail.
The thermoplastic resin (A) not forming an anisotropic molten phase used in the present invention may be any thermoplastic resin usually used, and examples thereof include polyolefin (co)polymer such as polyethylene, polypropylene and poly(4-methylpentene-1), polyester resin such as polyethylene terephthalate resin, polybutylene terephthalate resin and polycarbonate resin, polyamide polymer, syndiotactic polystyrene (SPS) resin, ABS resin, polyarylene sulfide resin, polyacrylarylate resin, polyacetal resin, polyphenylene oxide resin and a resin mainly comprising them. One or more of these resins may be used.
Among them, polyester resin such as polycarbonate resin and polybutylene terephthalate resin, SPS resin and polyarylene sulfide resin are preferable in respect of the thermal resistance, and the polycarbonate resin is especially preferable because it has relatively low molding shrinkage and linear expansion coefficient. Moreover, the polyester resin, especially the polycarbonate resin has the remarkable effect of the present invention in that, when an antimony compound or the like is used as usual, a catalytic activity acts in imparting a heat retentivity and a reaction to the liquid-crystal polymer tends to occur.
The thermoplastic resin of the present invention includes one provided with desired properties by adding additives to the thermoplastic resin, for example, nucleating agent, pigment such as carbon black, antioxidant, stabilizer, plasticizer, lubricant, mold releasing agent and flame retardant.
The liquid-crystal polymer (B) used in the present invention refers to a melt-processed polymer with the property that it can form an optically anisotropic molten phase.
The properties of an anisotropic molten phase can be confirmed by the conventional polarization inspection method using orthogonal polarizers. More specifically, confirmation of anisotropy in a molten phase can be attained by using a Leitz polarization microscope and observing a molten sample mounted on a Leitz hot stage under the nitrogen atmosphere at a magnification of 40 times. The liquid-crystal polymer usable in the present invention exhibits an optical anisotropy wherein a polarized light penetrates even in a static molten phase, when observed between cross polarizers.
As the liquid-crystal polymer usable in the present invention, aromatic polyester and aromatic polyester amide are an aromatic polyester or a liquid-crystal aromatic polyester amide containing at least one compound selected from the group consisting of aromatic hydroxycarboxylic acid, aromatic hydroxyamine and aromatic diamine.
More specifically, the followings are cited:
1) polyester or polyester amide mainly comprising one or two or more of aromatic hydroxycarboxylic acid, aromatic aminocarboxylic acid and derivatives thereof;
2) polyester or polyester amide mainly comprising
a) one or two or more of aromatic hydroxycarboxylic acid, aromatic aminocarboxylic acid and derivatives thereof,
b) one or two or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid, aliphatic dicarboxylic acid and derivatives thereof, and
c) one or two or more of aromatic diol, alicyclic diol, aliphatic diol and derivatives thereof;
3) polyester amide mainly comprising
a) one or two or more of aromatic hydroxycarboxylic acid, aromatic aminocarboxylic acid and derivatives thereof,
b) one or two or more of aromatic hydroxyamine, aromatic diamine and derivatives thereof, and
c) one or two or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid, aliphatic dicarboxylic acid and derivatives thereof;
4) polyester amide mainly comprising
a) one or two or more of aromatic hydroxycarboxylic acid, aromatic aminocarboxylic acid and derivatives thereof,
b) one or two or more of aromatic hydroxyamine, aromatic diamine and derivatives thereof,
c) one or two or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid, aliphatic dicarboxylic acid and derivatives thereof, and
d) one or two or more of aromatic diol, alicyclic diol, aliphatic diol and derivatives thereof;
5) polyester or polyester amide mainly comprising
a) one or two or more of aromatic hydroxycarboxylic acid, aromatic aminocarboxylic acid and derivatives thereof, and
b) one or two or more of aromatic dicarboxylic acid, alicyclic dicarboxylic acid, aliphatic dicarboxyl
Kobayashi Kazuhito
Murakami Haruji
Ohtake Mineo
Burns Doane , Swecker, Mathis LLP
Polyplastics Co. Ltd.
Szekely Peter
LandOfFree
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