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
2001-06-29
2004-11-02
Wyrozebski, Katarzyna (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...
C524S496000, C524S404000
Reexamination Certificate
active
06812275
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a thermoplastic resin composition which has an excellent fluidity and is able to form a molded product having a high elasticity.
PRIOR ART
In order to increase the modulus of elasticity of a molded product obtained from a thermoplastic resin, there has been already adopted a method where a filler such as carbon fiber, glass fiber, talc and mica is added. Among these fillers, carbon fiber has been used as the most effective means since the modulus of elasticity inherent thereto is very high and an effect of improving the modulus of elasticity resulting from its addition is high.
However, carbon fiber has a low specific gravity and, when its adding amount increases, its volume fraction in the resin significantly increases as compared with other fillers. Accordingly, as a result, fluidity of the resin lowers and the molding processability lowers. Especially in the case of molded substances (products) obtained from a material where high rigidity is required, many of them are then and, if the fluidity is low, there is a problem in processing. In addition, when reinforcement is carried out by a fibrous filler such as carbon fiber, there is another problem that warping caused by anisotropy in the shrinking rates arises.
DISCLOSURE OF THE INVENTION
An object of the present invention is to provide a thermoplastic resin composition which has none of the above-mentioned problems, shows a good molding ability due to its excellent fluidity and is able to yield a molded product having a high elasticity.
The present invention provides a thermoplastic resin composition comprising 90-30% by weight of (A) a thermoplastic resin, 5-60% by weight of (B) a fibrous filler and 5-60% by weight of (C) a whisker.
Examples of the thermoplastic resin which is the component (A) used in the present invention is one or more selected from a group consisting of a polyamide, styrene polymer, polyester, polyurethane, polyether, polyester ether, polyamide ether, polyphenylene oxide and polycarbonate. Among them, one or more selected from a styrene polymer, polyamide, polyester and polycarbonate are preferable, and a polyamide and a styrene polymer are more preferable.
As the polyamide, one or more selected from a polyamide resin formed from a diamine and a dicarboxylic acid and copolymers thereof such as Nylon 66, polyhexamethylene sebacamide (Nylon 610), polyhexamethylene dodecamide (Nylon 612), polydodecamethylene dodecamide (Nylon 1212), poly-m-xylylene adipamide (Nylon MXD6), polytetramethylene adipamide (Nylon 46) and mixtures and copolymers thereof; a copolymer such as Nylon 6/66, Nylon 66/6T, where a 6T component is not more than 50 molar % (6T: polyhexamethylene terephthalamide), Nylon 66/6I, where a 6I component is not more than 50 molar % (6I:
polyhexamethylene isophthalamide), Nylon 6T/6I/66 and Nylon 6T/6I/610; aromatic polyamide resin such as polyhexamethylene terephthalamide (Nylon 6T), polyhexamethylene isophthalamide (Nylon 6I), poly(2-methylpentamethylene) terephthalamide (Nylon M5T) and poly(2-methylpentamethylene) isophthalamide (Nylon M5I); and copolymers such as Nylon 6T/6I and Nylon 6T/M5T may be proposed.
Further, as the polyamide, one or more selected from an open-ring polymer of cyclic lactam, a polycondensate of aminocarboxylic acid and a copolymer thereof such as an aliphatic polyamide resin and copolymers thereof such as Nylon 6, poly-&ohgr;-undecanamide (Nylon 11) and poly-&ohgr;-dodecamide (Nylon 12); and a copolymer with a polyamide comprising dicarboxylic acid and a diamine such as Nylon 6T/6, Nylon 6T/11, Nylon 6T/12, Nylon 6T/6I/12 and Nylon 6T/6I/610/12 may be proposed.
As the styrene polymer, a polymer of styrene and a styrene derivative such as an a-substituted styrene and a nuclear-substituted styrene and a copolymer prepared from the above monomer with another monomer such as a vinyl compound (including acrylonitrile, acrylic acid and methacrylic acid) and/or a conjugated diene compound (such as butadiene and isoprene) may be proposed. As the styrene polymer, polystyrene, high-impact polystyrene (HIPS), acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene copolymer (AS resin), styrene-methacrylate copolymer (MS resin), styrene-butadiene copolymer (SBS resin) etc. Are preferable.
Further, in order to improve the compatibility of the polyamide with the styrene polymer, a styrene copolymer in which a carboxyl-containing unsaturated compound is copolymerized may be compounded as a part of the styrene copolymer.
The styrene copolymer in which the carboxyl-containing unsaturated compound is copolymerized is a copolymer where the carboxyl-containing unsaturated compound and, if necessary, other monomer which is copolymerizable therewith is/are polymerized in the presence of a rubber polymer, and the following may be proposed.
(1) a graft polymer which is prepared by polymerizing a monomer where an aromatic vinyl is an essential component or a monomer where an aromatic vinyl and a carboxyl-containing unsaturated compound are essential components in the presence of a rubber polymer copolymerized with a carboxyl-containing unsaturated copolymer;
(2) a graft copolymer which is prepared by copolymerizing a monomer where an aromatic vinyl and a carboxyl-containing unsaturated compound are essential components in the presence of a rubber polymer;
(3) a mixture of a rubber-enriched styrene resin where a carboxyl-containing unsaturated compound is not copolymerized and a monomer where an aromatic vinyl and a carboxyl-containing unsaturated compound are essential components;
(4) a mixture of the above (1) and (2) and a copolymer where an aromatic vinyl and a carboxyl-containing unsaturated compound are essential components; and
(5) a mixture of the above (l)-(4) and a copolymer where an aromatic vinyl is an essential component.
In the above-mentioned (l)-(5), styrene is preferable as an aromatic vinyl, while acrylonitrile is preferable as a monomer which is copolymerized with the aromatic vinyl. The amount of the styrene polymer in which the carboxyl-containing unsaturated compound is copolymerized in the component (A) is preferably 0.1-8% by weight, and more preferably 0.2-7% by weight.
The amount of the component (A) in the composition is 90-30% by weight, preferably 90-40% by weight, and more preferably, 90-50% by weight.
As the fibrous filler which is the component (B) used in the present invention, carbon fiber, glass fiber and other inorganic fibers (such as silicon carbide fiber and alumina fiber) may be proposed. Among them, carbon fiber is preferable when the manufacturing cost and the reinforcing effect are taken into consideration. As the carbon fiber, carbon fibers of a cellulose, a PAN, a pitch etc. May be proposed.
The amount of the component (B) in the composition is 5-60% by weight, preferably 5-50% by weight and more preferably 5-40% by weight, so that the fluidity of the composition and mechanical strength of the molded product, etc. Are synergistically heightened by combination with the component (C).
The whisker which is the component (C) used in the present invention is a component which achieves a synergistic effect by combination with the component (B), particularly with carbon fiber and may be a metal or non-metal. For example, aluminum borate, silicon carbide, silicon nitride, potassium titanate, basic magnesium sulfate, zinc oxide, graphite, magnesia, calcium sulfate, sodium calcium phosphate, magnesium borate, titanium diborate, &agr;-alumina, chrysotile, wollastonite, etc. May be proposed.
Since the whisker is to suppress the increase of the total volume of the composition and to improve the fluidity, the more its specific gravity, the better. The gravity of the whisker is preferably 2 or more, 2.5 or more is more preferable and 2.9 or more is further preferable.
The amount of the component (C) in the composition is 5-60% by weight, preferably 5-50% by weight and more preferably 5-30% by weight, so that fluidity of the composition, mechanical strength of the molded product, etc. Are s
Daicel Chemical Industries Ltd.
Flynn ,Thiel, Boutell & Tanis, P.C.
Wyrozebski Katarzyna
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