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
1999-05-19
2001-10-16
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...
C524S520000, C525S199000
Reexamination Certificate
active
06303686
ABSTRACT:
This application is the national phase under 35 U.S.C. §371 of prior PCT International Application No. PCT/JP97/03218 which has an International filing date of Sep. 12, 1997 which designated the United States of America.
1. Field of the Invention
The present invention relates to a resin composition and a resin molded article produced from said resin composition.
2. Related Arts
Hitherto, in making a thermoplastic resin flame resistant, it is known that for the purpose of preventing to dripping at the time of combustion and of increasing flame retardancy, fibrillated polytetrafluoroethylene (PTFE) together with a flame-retardant is added to the thermoplastic resin to compound a flame-retardant resin.
The amount of PTFE added to such flame-retardant thermoplastic resin is an amount which is as low as about 0.1 to 1.0% by weight, but is sufficient to exhibit the prevention of dripping at the time of combustion.
However, because PTFE does not have affinity for other materials, there is the disadvantage that its addition even in such a small amount significantly lowers the impact strength of thermoplastic resin.
Further, PTFE is added for the purpose of conferring sliding properties on the thermoplastic resin. The addition amount in this case is varied depending on sliding use and the type of thermoplastic resin. As to low-sliding use, for e.g. CD-ROM tray materials such as in personal computers, PTFE is added in an amount of 2 to 5% by weight to an acrylonitrile/butadiene/styrene (ABS) resin, and even for gears used in OA (office automation) instruments, PTFE is added in an amount of about 5% by weight to a polycarbonate resin.
As to high-sliding use, e.g. in bearing materials, there are also cases where PTFE is added in an amount of 20 to 50% by weight to polyphenylene sulfide.
Even in cases where PTFE is added in a relatively large amount, there is the disadvantage of reduction in impact strength.
Further, hitherto, when connectors and sockets used in electrical and electronic parts are produced, terminals are attached by soldering to a connector resin and by passing the terminal through a through-hole. Due to capillarity, the flux used is passed through the through-hole and raised to the terminal. Because acidic components are contained in the flux, they can be the cause of terminal corrosion to cause a contact failure and the like.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a resin composition which has excellent impact strength and repels a flux well.
The present invention provides a resin composition comprising:
(a) a fluorine-free thermoplastic resin,
(b) a fluorine-containing resin which is a homopolymer, modified polymer or core/shell polymer of tetrafluoroethylene, and
(c) a polyfluoroalkyl group-containing polymer.
The resin composition of the present invention may further comprise (d) a flame-retardant.
The present invention further provides a resin molded article produced from said resin composition.
DETAILED DESCRIPTION OF THE INVENTION
The fluorine-free resin (a) is a thermoplastic resin or thermosetting resin having no fluorine atom.
The thermoplastic resin includes a styrene-type resin (e.g. polystyrene, acrylonitrile/styrene resin (AS), acrylonitrile/butadiene/styrene resin (ABS)); an olefin-type resin (e.g. polyethylene, polypropylene, polymethylpentene); polyvinyl chloride; a carbonate-type resin (e.g. polycarbonate (PC), a PC-type alloy resin such as a polycarbonate-acrylonitrile/butadiene/styrene alloy resin (PC/ABS)); a polyamide-type resin (e.g. nylon, wholly aromatic polyamide); a polyester-type resin (e.g. polybutylene terephthalate, polyethylene terephthalate, wholly aromatic polyester); a polyamide-type alloy resin; a polyester-type alloy resin; an acrylic resin (e.g. polymethyl methacrylate, polyacrylonitrile); polyacetal; polyether ether ketone; and polyphenylene sulfide; modified polyphenylene ether.
The thermosetting resin includes an epoxy resin; a phenol resin; a urea resin; a melamine resin; an alkyd resin; an unsaturated polyester resin; diallyl phthalate (DAP) resin; polyurethane; and a silicone resin.
The weight average molecular weight of the fluorine-free resin (a) may be from 1000 to 1,000,000.
The fluorine-containing resin (b) may be a homopolymer, modified polymer or core/shell polymer of tetrafluoroethylene (TFE). The fluorine-containing resin (b) may be fine powder obtained by emulsion polymerization or molding powder obtained by suspension polymerization.
The modified polymer of tetrafluoroethylene is a copolymer prepared by copolymerizing the following modifying monomers in an amount of 0.001 to 1.0% by weight (based on the copolymer). The modifying monomers used in the modified polymer include e.g. hexafluoropropylene, trifluoromonochloroethylene, perfluorovinyl ether, and fluoroalkyl ethylene. The core/shell polymer is described in e.g. Japanese Patent Kokai Publication Nos. 154,842/1992, 158,651/1990, 274,711/1990, 247,408/1989, and 312,836/1988.
The core/shell polymer includes e.g. (i) polytetrafluoroethylene fine particles having an average particle size of 0.05 to 1.0 &mgr;m comprising a core made of high-molecular-weight polytetrafluoroethylene that can be fibrillated and a shell made of low-molecular-weight polytetrafluoroethylene that can not be fibrillated and (ii) fine particles having an average particle size of 0.05 to 1.0 &mgr;m comprising a core, that is, a polymer made of 99 to 100% by weight of tetrafluoroethylene and 0 to 1% by weight of a fluorine-containing olefin copolymerizable with tetrafluoroethylene, and a shell, that is, at least one copolymer selected from the group consisting of ethylene/tetrafluoroethylene copolymers, ethylene/chlorotrifluoroethylene copolymers, tetrafluoroethylene/ethylene/hexafluoropropylene copolymers, tetrafluoroethylene/hexafluoropropylene copolymers, tetrafluoroethylene/perfluorovinyl ether copolymers, tetrafluoroethylene/hexafluoropropylene/perfluorovinyl ether copolymers and vinylidene fluoride/tetrafluoroethylene copolymers.
The fluorine-containing resin (b) may be low-molecular-weight (e.g. a weight average molecular weight of 1×10
4
to 8×10
5
) tetrafluoroethylene homopolymers and modified polymers.
The fluorine-containing resin (b) may be tetrafluoroethylene/hexafluoropropylene copolymers (FEP), tetrafluoroethylene/perfluorovinyl ether copolymers (PFA), ethylene/tetrafluoroethylene copolymers (ETFE), polyvinylidene fluoride (PVdF), tetrafluoroethylene/ethylene/hexafluoropropylene copolymers, tetrafluoroethylene/hexafluoropropylene/perfluorovinyl ether copolymers, and vinylidene fluoride copolymers. A comonomer copolymerized with vinylidene fluoride in vinylidene fluoride copolymers includes tetrafluoroethylene (TFE), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), trifluoromonochloroethylene (TrFE), and a combination thereof
The weight average molecular weight of the fluorine-containing resin (b) may be from 1×10
3
to 1×10
7
.
The amount of the fluorine-containing resin (b) may be from 0.01 to 100 parts by weight, based on 100 parts by weight of the fluorine-free resin (a). The amount is preferably varied depending on the desired use. For example, in order to confer the dripping prevention properties on the thermoplastic resin, the amount is preferably from 0.1 to 5.0 parts by weight. To confer the sliding properties, the amount is preferably from 2 to 60 parts by weight.
The polyfluoroalkyl group-containing polymer (c) may be a homopolymer of a polyfluoroalkyl group-containing monomer or a copolymer of said monomer and a comonomer copolymerizable therewith.
The polyfluoroalkyl group-containing monomer may be compounds described in Japanese Patent Kokai Publication Nos. 41162/1991 and 7745/1991. The polyfluoroalkyl group-containing monomer may be polyfluoroalkyl group-containing (meth)acrylate. Examples of polyfluoroalkyl group-containing (meth)acrylate are as follows:
CH
2
═CHCOOC
2
H
4
(CF
2
CF
2
)
n
CF
2
CF
3
CH
2
═C(CH
3
)COOC
2
H
4
(CF
2
CF
2
)
n
CF
2
CF
3
CH
2
═C(CH
3
)COOC
2
H
4
(CF
2
C
Honda Yoshitaka
Kitahara Takahiro
Yamaguchi Fumihiko
Birch & Stewart Kolasch & Birch, LLP
Daikin Industries Ltd.
Szekely Peter
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