JP2000248179A - Manufacture of polyphenylene sulfide resin composition having continuous phase structure, and manufacture of molding, mat-shape material and fiber-shape material comprising the resin composition - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a polyphenylene sulfide(PPS) resin composition having a stable continuous phase structure, in a mixed resin type containing PPS as an essential component, and to provide a molding with greatly improved mechanical properties such as impact resistance, mechanical strength, and breaking extension. SOLUTION: Manufacture of a polyphenylene sulfide(PPS) resin composition having a continuously ranging structure of compounded each resin comprises melt kneading 30-70 wt.% PPS and 70-30 wt.% thermoplastic resin selected from the group consisting of a polycarbonate, polysulfone, and polyether keton at a rotational speed of at least 0.3 m/sec of a linear speed in an outer periphery part of a screw used for melt kneading.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a polyphenylene sulfide resin which is excellent in impact resistance, breaking strength and breaking elongation and is used in various fields as electric / electronic parts, precision parts, automobile parts and various molding materials. The present invention relates to a method for producing a composition, and more particularly, to a method for producing a polyphenylene sulfide resin composition that forms a continuous phase structure in which each of the blended resins is continuously connected in the composition.

[0002]

2. Description of the Related Art Polyphenylene sulfide (hereinafter referred to as "P
PS ”. ) Has a heat resistance close to 300 ° C, and has outstanding dimensional stability and chemical resistance, so it is attracting attention as an engineering plastic material that can be used as a substitute for metal, and is used for automobile parts, electronic / electric parts, precision parts It is used in such fields.

[0003] However, it is known that PPS is the most disadvantageous in that it is brittle, poor in impact resistance and mechanical properties. In most cases, PPS is used in combination with an inorganic reinforcing agent such as glass fiber or silica. Has been used. For this reason, the field of use as a molding material is currently limited.

[0004] A method of blending another thermoplastic resin for the purpose of improving the toughness of PPS has long been known. For example, JP-A-60-229949 discloses a polyethylene-based resin, JP-A-58-145557 discloses a glycidyl-modified polyolefin-based resin, and JP-A-60-120.
No. 753 discloses a rubbery compound disclosed in JP-A-51-628.
No. 49 discloses a polystyrene-based resin disclosed in JP-A-59-5.
JP-A-8052 discloses a thermoplastic polyester resin, JP-A-51-59952 discloses a polycarbonate-based resin, JP-A-50-156561 discloses a polyphenylene ether-based resin, and JP-A-53-69255 describes a resin. Japanese Patent Application Laid-Open No. Sho 60-255846 discloses a method in which a polyamide resin is blended with PPS, and a polyetherketone resin is blended with PPS. However, no matter which resin is used, compatibility with PPS is poor, and at present, a sufficient effect has not been obtained.

[0005] The above-mentioned mixed systems of PPS are all mixtures of mutually incompatible resins, and the phase structure of the mixture is all sea-island structure. Normally, the larger volume fraction is the sea phase, and the other is dispersed as the island phase in the sea phase. In the case of such a structure, as a method for improving the mechanical properties and the like, there is a method of making the dispersed particle diameter as small as possible and increasing the adhesion at the interface. In order to improve the adhesiveness of the interface, a method using a silane coupling agent such as epoxysilane or aminosilane, a method using an epoxy resin, a method of adding a block copolymer, and the like have been studied.

On the other hand, attempts have been made to improve the mechanical properties and the like by controlling the structure of the mixed resin in the mixed state. For example, "Molding" (Vol. 8, page 24 (1996)) states that polycarbonate and AB
In a mixed resin system composed of S resin and the like, as a result of phase separation when injection-molding a compatibilized material in a melt-kneaded state using high shear stress, the resulting molded product has a co-continuous modulation structure. It is disclosed that mechanical properties such as impact strength are greatly improved.

However, mixed resin systems that are compatibilized by high shear stress are extremely rare, and almost all tens of thousands of mixed resin systems, including PPS as an essential component, have even a phase diagram. It is a completely incompatible system that cannot
Even when melt-kneaded in a high shear stress field, they are compatible and do not mix at the molecular level. Therefore, it was impossible to control the structure of the mixed resin in the mixed state by such a method.

[0008] Also, "Polymer Alloy Fundamentals and Applications (2nd Edition) (Chapter 10)" (Polymer Society of Japan, Tokyo Chemical Doujinshi)
For example, in a mixed resin system that is incompatible with each other, if the volume fraction of the island phase is gradually increased, the sea phase and the island phase are reversed at a certain point, and near this composition, both phases become sea phases. It has been reported that a continuous phase structure (co-continuous structure) is developed. If the mixed resin-based phase-separated structure is not a simple sea-island structure but a continuous phase structure, the mechanical properties of the molded product are significantly different from those of the sea-island structure, and it is expected that the characteristics are improved. However, when there is no information other than that the sea-island phase is in the vicinity of the composition region where the sea-island phase is reversed, and the composition seems to satisfy the condition by chance, rarely, In some cases, a continuous phase structure was observed in a small part, but it was not possible to stably obtain a continuous phase structure under normal melt molding conditions even when molding near the composition region where the sea-island phase was reversed. .

[0009]

An object of the present invention is to provide a method for producing a polyphenylene sulfide resin composition having a stable continuous phase structure in a mixed resin system containing PPS as an essential component. An object of the present invention is to provide a molded article having greatly improved mechanical properties such as impact properties, mechanical strength, and elongation at break.

[0010]

The present inventors have conducted intensive studies to solve the above-mentioned problems, and as a result, a very high mixed resin system of PPS and polysulfone, polycarbonate or polyetherketone has been found. It has been found that the desired continuous phase structure can be obtained when melt-kneading at a high speed, and the present invention has been completed.

That is, the present invention provides (I) (1) polyphenylene sulfides 30 to 7 for solving the above problems.
0% by weight and (2) a rotational speed of 0.3 m / sec or more at the outer peripheral portion of a screw used for melting and kneading 70 to 30% by weight of a thermoplastic resin selected from the group consisting of polycarbonate, polysulfone and polyether ketone. Disclosed is a method for producing a polyphenylene sulfide resin composition having a structure in which each compounded resin that is melt-kneaded at a high speed is continuously connected.

Further, in order to solve the above-mentioned problems, the present invention comprises (II) injection molding the polyphenylene sulfide resin composition obtained by the production method described in the above (I) at a speed of 5 cm / sec or more. Provided is a method for producing a molded product comprising a polyphenylene sulfide resin composition having a structure in which each resin is continuously connected.

Further, the present invention provides a method for solving the above-mentioned problems: (III) (1) polyphenylene sulfide
Polyphenylene sulfide resin composition obtained by melt-kneading 70% by weight and (2) 70 to 30% by weight of polycarbonate or polysulfone at a rotation speed at which a linear velocity at an outer peripheral portion of a screw used for melt-kneading is 0.3 m / sec or more. Injection molding of a product at a speed of 5 cm / sec or more, from the removal of polycarbonate and polysulfone using an organic solvent from a molded product composed of a polyphenylene sulfide resin composition having a structure in which each compounded resin is continuously connected. The present invention provides a method for producing a mat-like material made of polyphenylene sulfide.

Furthermore, the present invention provides (IV) (1) a polyphenylene sulfide 30 for solving the above-mentioned problems.
Polyphenylene sulfide resin obtained by melt-kneading at a rotational speed of 0.3 m / sec or more at the outer peripheral portion of a screw used for melt-kneading 70 to 30 wt% of polycarbonate or polysulfone (2). Provided is a method for producing a polyphenylene sulfide fibrous material having a fiber diameter of 1 μm or less, which comprises melt-spinning a composition at a draft ratio of 2 to 20, and then removing polycarbonate and polysulfone using an organic solvent. I do.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION The PPS used in the present invention is a polymer having a repeating unit represented by the formula [-φ-S-] (wherein -φ- is a p-phenylene group) in an amount of 70 mol% or more. Preferably, there is. If the content of the repeating unit is less than 70 mol%, the crystallinity tends to be low, and the strength and the chemical resistance tend to be greatly reduced.

The copolymer units which may be contained in the PPS used in the present invention in a proportion of less than 30 mol% include:
For example, a copolymer structural unit represented by the following formula may be mentioned.

[0017]

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[0018]

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[0019]

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[0020]

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[0021]

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[0022]

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[0023]

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[0024]

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[0025]

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The PPS used in the present invention is at 300 ° C.
The complex viscosity (η ^* ) measured at 100 rad / sec is 10
Those having a range of 1000 Pa · s are preferable, and 20 to 70
Those having a range of 0 Pa · sec are particularly preferred.

[0027] PPS is generally prepared by the following method.
PPS having a molecular structure that is substantially linear and does not have a branched or cross-linked structure and a structure having a branched or cross-linked structure are known, and the PPS used in the present invention is any of those types. Or a commercially available PPS.

The polycarbonate (hereinafter abbreviated as PC) used in the present invention is a polymer composed of a dihydric phenol unit and a carbonic acid unit. Among these, PC composed of a bisphenol A unit and a carbonic acid unit, PC and dihydroxy-
P consisting of diphenyl-cyclohexane unit and carbonic acid unit
C is particularly preferred. As a commercial product of such a PC,
For example, "Iupilon" manufactured by Mitsubishi Gas Chemical Co., Ltd. and the like can be mentioned.

The polysulfone (hereinafter referred to as P) used in the present invention
Abbreviated as SF. ) Is a polyether containing 4,4′-diphenylsulfone, and among them, PSF obtained from bisphenol A and 4,4′-dichlorodiphenylsulfone is particularly preferred. Examples of such a commercially available PSF include "Udel" manufactured by Amoco.

The polyetherketone (hereinafter abbreviated as PEK) used in the present invention has the formula [-φ-CO-φ-O
-] (In the formula, -φ- is a p-phenylene group) is a polymer containing in the main chain a unit represented by the formula [-φ-CO-φ-O-φ-O-] PEK containing a unit represented by the following formula in the chief examiner is particularly preferred. Such a PEK
Examples of commercially available products include “VICTREX-PEEK” manufactured by ICI.

PC, PSF and PEK used in the present invention
The melt viscosity of is not particularly limited as long as it is within the range of ordinary commercial products. As shown in Examples, in the case of PC and PSF, melt-kneading is performed at around 300 ° C. 300 ° C, 1
The complex viscosity at 00 rad / sec is 42 Pa ·
In seconds, PSF is 900 Pa · s and PC is 380 Ps
a · sec. Further, in the case of PEK, melt kneading is performed at around 350 ° C. 350 ° C, 100 rad /
The complex viscosity in seconds is 14 Pa · s for PPS,
PEK is 860 Pa · s, which is nearly 60 times different. In addition, polypropylene (PP) at 300 ° C. and 100 rad
The complex viscosity at 400 g / sec was 400 Pa · s, which was almost the same as that of PC. However, even when PPS and PP were melt-kneaded at a high rotation speed, a sea-island structure was not obtained, and a continuous phase structure was not obtained. Furthermore, polyethylene terephthalate (PET) 3
The complex viscosity at 100 ° C. and 100 rad / sec is 55 Pa ·
Seconds, which was almost the same as 42 Pa · s of PPS, but when PPS and PET were melt-kneaded at a high rotation speed, a sea-island structure was formed, and a continuous phase structure was not developed. From these results, it is presumed that the structural factor is more important than the viscosity factor for the development of the continuous phase structure.

The mixed composition of the composition of the present invention is (A) PPS
Is 30 to 70% by weight, and (B) 70 to 30% by weight of a thermoplastic resin selected from the group consisting of PC, PSF and PEK.
(A) PPS is 35 to 65% by weight,
(B) The range of 65 to 35% by weight of the thermoplastic resin selected from the group consisting of PC, PSF and PEK is particularly preferred. If the PPS content is less than 30% by weight or more than 70% by weight, a continuous phase structure cannot be obtained even by the production method of the present invention, which is not preferable.

The resin composition of the present invention comprises (A) PPS,
(B) It is obtained by melt-kneading a thermoplastic resin selected from the group consisting of PC, PSF and PEK at a rotation speed at which the linear velocity at the outer peripheral portion of the screw used for melt-kneading is 0.3 m / sec or more. A molded product using this resin composition has a phase-separated structure that forms a sea-island structure under conventional conditions,
It is possible to provide a molded article which forms a continuous phase structure in which both (A) PPS and (B) a thermoplastic resin component other than PPS are continuously connected.

The term “continuous phase structure” as used in the present invention refers to a structure in which both components of a polymer to be mixed form a continuous phase and are three-dimensionally entangled with each other. Both phases are continuously spread with a diameter of at least several μm, and have a complicated structure entangled irregularly. A schematic diagram of this continuous phase structure is described, for example, in "Polymer Alloy Fundamentals and Applications (Second Edition) (Chapter 10.1)" (edited by The Society of Polymer Science, Tokyo Chemical Dojin).

The molding method of the present invention can be any method, and the molding shape can be any shape. Examples of the molding method include injection molding, extrusion molding, inflation molding, blow molding, and spinning. As these molding machines, a normal type molding machine can be used, but a molding machine having a capability of providing a linear velocity of 0.3 m / sec or more on the outer periphery of the screw at a portion where the resin of the molding machine is kneaded is used. The linear velocity of the outer periphery of the screw at the time of kneading the resin, which is a technical point of the present invention, is given by a value obtained by multiplying the outer periphery (diameter × circumferential ratio) of the screw of the portion where the resin of the molding machine is kneaded by the rotation speed. In normal molding, the linear velocity at the outer periphery of the screw is 0.1 to 0.15 m / sec. When melt-kneaded at a speed of less than 0.3 m / sec, a sea-island structure is formed and a stable continuous phase structure cannot be obtained. The upper limit of the linear velocity on the outer circumference of the screw is determined from the viewpoint of melt fracture (breaking of molecular chains in the molten state) and the structure of the device.
Naturally, there are limits, but the limits vary greatly depending on the molecular weight of the polymer material used, the molding temperature, etc. In addition, the linear velocity on the outer periphery of the screw is high in order to develop the continuous phase structure formed in the present invention. Since there is no inconvenience due to being too long, it is not particularly necessary to set an upper limit.

The molding temperature depends on the thermoplastic resin used, but the PPS / PC system usually has a molding temperature of 280 to 340 ° C.
PS / PSF system is usually 280-360 ° C, PPS / PE
The K system is usually performed at 340 to 380 ° C. As the molding temperature increases, the structural period of the continuous phase structure tends to increase, but the presence or absence of the development of the continuous phase structure is not affected and the usual molding temperature is not limited.

The injection speed of the resin must be 5 cm / sec or more. When the injection is performed at a very low speed of less than 5 cm / sec, the PPS resin composition of the present invention changes to a sea-island structure, and a stable continuous phase structure cannot be obtained. However, when injection molding is generally performed at a speed of 5 cm / sec or more, a continuous phase structure can be stably obtained, and the continuous phase structure does not disappear to form a sea-island structure.

The mold temperature and mold shape are not particularly limited.
For example, when the mold temperature is set to 220 ° C., although the structural period of the obtained continuous phase structure tends to be slightly larger, there is no influence on the presence or absence of the co-continuous structure.

A composition obtained by discharging the resin composition from a melt molding machine into the air without putting it in a mold and allowing it to cool in the air, or a composition rapidly discharged and cooled in water, that is, melt extrusion molding A continuous phase structure is also formed on the object as a whole. In the present invention, it can be confirmed from experimental results that any method and shape can be applied to the forming method and the formed shape.

In the production method of the present invention, when PC or PSF is used as the thermoplastic resin that is melt-kneaded with PPS, the obtained molded product or film is immersed in an organic solvent in which PC or PSF is soluble. PC or P depending on the method
By removing the SF, it is possible to obtain a PPS filter or a mat-like material in which PPSs are connected in a network.

Organic solvents in which PC and PSF are soluble include:
For example, halogen solvents such as chloroform and methylene chloride; N, N-dimethylacetamide, N-methyl-2
Amide solvents such as pyrrolidone; ketone solvents such as acetone and methyl ethyl ketone; aromatic hydrocarbons such as toluene and xylene.

Further, in the method for producing a PPS resin composition of the present invention, instead of injecting the PPS resin composition into a mold,
It is also possible to extrude the PPS resin composition from the nozzle and wind it up on a bobbin or the like to form a fibrous material. In particular, when PC or PSF is used as the thermoplastic resin, after drafting is performed at a low ratio of 2 to 20 at low magnification, the obtained fibrous material is immersed in an organic solvent in which PC or PSF is soluble. By this method, PC and PSF can be removed, and a PPS fibrous material having a diameter of 1 μm or less can be easily obtained. In this case, if the fiber is spun at a draft ratio of 20 times or more to achieve fiberization, it may not be possible to easily remove PC or PSF by immersion in a solvent. Further, the PPS fiber obtained by this method is different from conventionally known co-extruded spun fiber, and has a network structure in which the fiber is partially bonded, and thus is a suitable material as a nonwoven fabric or filter paper.

Further, the PPS resin composition of the present invention may optionally contain a reinforcing material and a filler.

The reinforcing material and filler that can be oriented in the PPS resin composition of the present invention include powdery, flat, scaly, acicular, spherical, hollow, and fibrous materials. Specifically, calcium sulfate, calcium silicate, clay, talc, alumina, silica, titania, silica sand, glass powder,
Metal powder, graphite, silicon carbide, silicon nitride, boron nitride, aluminum nitride, powdered particulate fillers such as carbon black; mica, glass plate, sericite, metal foils such as aluminum flakes, flat plates such as graphite or Flaky filler; hollow filler such as shirasu balloon, metal balloon, glass balloon; fibrous filler such as glass fiber, carbon fiber, graphite fiber, whisker, metal fiber, asbestos, wollastonite; aromatic polyamide fiber And organic fibrous fillers such as

Further, the PPS resin composition of the present invention contains P
For the purpose of improving the compatibility between PS and PC, PPS and PSF, PPS and PEK, bisoxazoline compounds, epoxy resins, epoxy group-containing thermoplastic resins, oxazoline group-containing thermoplastic resins, or epoxy groups, amino groups, and mercapto groups A silane coupling agent or a titanium coupling agent containing at least one vinyl group or isocyanate group can also be blended.

Further, the PPS resin composition of the present invention may contain an inorganic flame retardant such as magnesium hydroxide, aluminum hydroxide, antimony trioxide, an antioxidant, a lubricant, a dispersant within a range not departing from the gist of the invention. Additives such as a coupling agent, an ultraviolet inhibitor, a foaming agent, a crosslinking agent, a coloring agent, and a plasticizer can also be added.

[0047]

The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to the scope of the following examples.

Example 1 PPS (“LN-1” manufactured by Topren Co., Ltd., complex viscosity = 42 Pa · s) and PS
F (“UDEL P3707” manufactured by Amoco Co., complex viscosity = 900 Pa · s) (mixing weight ratio = 1: 1) at 320 ° C., and a linear velocity of 0.8 m / s on the outer periphery of the screw for the first 3 minutes (The distance between the screw and barrel is 6
mm), and for the next 2 minutes, a linear velocity of 0.
After melt-kneading at 4 m / sec, it was continuously injection-molded at a speed of 20 cm / sec to obtain a plate-like molded product.

The complex viscosity of the resin used is a value measured at 300 ° C. and 100 rad / sec using a melt viscoelasticity measuring device RDS-II manufactured by Rheometrics.

(Example 2) A plate-like molded product was obtained in the same manner as in Example 1 except that the kneading conditions were changed to a linear velocity of 0.8 m / sec on the outer periphery of the screw for 5 minutes. Was.

(Comparative Example 1) In Example 1, the kneading conditions were changed for the first three minutes to a linear velocity of 0.8 m /
And the next 2 minutes with a linear velocity of 0.1 around the screw.
A plate-like molded product was obtained in the same manner as in Example 1 except that the speed was 5 m / sec.

(Comparative Example 2) The procedure of Example 1 was repeated except that the kneading conditions were such that the linear velocity of the outer periphery of the screw was 0.8 m / sec for 5 minutes and the injection speed was 0.03 m / sec. In the same manner as in the above, a plate-like molded product was obtained.

The molded articles obtained in Examples 1 and 2 and Comparative Example 1 were subjected to a bending test and an Izod (IZOD) impact test under the following conditions. The results are shown in Table 1 below. Table 1 also shows the results of observing the fractured cross section generated as a result of the impact test with a scanning electron microscope (SEM).

(Bending test) width = 10 mm, length = 50 mm,
A test piece having a thickness of 2 mm was used, and a span length was 30 mm and a speed was 2 mm / min using a Shimadzu autograph.

(Izod test) width = thickness = 3.5 mm,
The test was performed without a notch using a test piece having a length of 3 mm.

[0056]

[Table 1]

From the results shown in Table 1, the molded products obtained in Comparative Examples 1 and 2 have significantly higher mechanical properties, impact resistance and elongation at break than the molded products obtained in Examples 1 and 2. It can be understood that it has decreased.

(Example 3) PPS and PC used in Example 1 ("Iupilon S-20" manufactured by Mitsubishi Gas Chemical Co., Ltd.)
00 ”, complex viscosity = 380 Pa · sec) (mixing weight ratio =
6: 4) at 300 ° C. at a linear velocity of 0.
After melt-kneading at 5 m / sec, the mixture was injected at a speed of 20 cm / sec to obtain a plate-like molded product.

(Comparative Example 3) A plate-like molded product was obtained in the same manner as in Example 3, except that the linear velocity on the outer periphery of the screw was changed to 0.15 m / sec.

The plate-like molded products obtained in Example 3 and Comparative Example 3 were subjected to a bending test in the same manner as in Example 1, and the results are shown in Table 2 below. In addition, as a result of the impact test, the fractured cross section generated was examined using a scanning electron microscope (SEM).
Table 2 also summarizes the observation results.

[0061]

[Table 2]

From the results shown in Table 2, the molded product obtained in Comparative Example 3 is different from the molded product obtained in Example 3 in mechanical properties and
In particular, it can be understood that the impact resistance and the elongation at break are significantly reduced.

Example 4 The PPS and PEEK (Victrex-PEEK-380G manufactured by ICI) (mixed weight ratio = 1: 1) used in Example 1 were heated at 350 ° C. Then, after melt kneading at a linear velocity of 0.6 m / sec on the outer periphery of the screw, injection was performed at a velocity of 20 cm / sec to obtain a plate-like molded product. Note that PPS and PEEK
The complex viscosity at 350 ° C. and 100 rad / sec was 14 Pa · sec and 860 Pa · sec, respectively.

(Comparative Example 4) A plate-like molded product was obtained in the same manner as in Example 4, except that the linear velocity on the outer periphery of the screw was changed to 0.15 m / sec.

The plate-like molded products obtained in Example 4 and Comparative Example 4 were subjected to a bending test in the same manner as in Example 1, and the results are shown in Table 3 below. In addition, as a result of the impact test, the fractured cross section generated was examined using a scanning electron microscope (SEM).
Table 3 also summarizes the results of the observation.

[0066]

[Table 3]

From the results shown in Table 3, the molded product obtained in Comparative Example 4 is different from the molded product obtained in Example 4 in mechanical properties and
In particular, it can be understood that the impact resistance and the elongation at break are significantly reduced.

(Example 5) PPS and PC used in Example 1 (Iupilon S-20 manufactured by Mitsubishi Gas Chemical Co., Ltd.)
00) (mixing weight ratio = 1: 1) was melt-kneaded at 310 ° C. at a linear velocity of 0.6 m / sec on the outer periphery of the screw.
Injection was performed at a speed of cm / sec, and the spun yarn was spun at a draft ratio of 5 with a diameter of about 1 mm.

The spun yarn thus obtained was cut into a length of about 5 cm, placed in chloroform to dissolve PC, and then removed with filter paper. As a result of observing the filtrate with a scanning electron microscope (SEM), it was possible to observe that PPS fibers having a diameter of 1 μm or less were partially bonded.

(Example 6) The PPS and PSF used in Example 1 ("UDEL P370" manufactured by Amoco Co., Ltd.)
7)) (mixing weight ratio = 1: 1) was melt-kneaded at 320 ° C. at a linear velocity of 0.7 m / sec on the outer periphery of the screw, and then continuously injected at a speed of 40 cm / sec to obtain a 2 mm thick sheet. A sheet-like molded product was obtained.

The sheet-like molded product thus obtained was immersed in methylene chloride to dissolve the PSF. Scan the surface and cross section of the obtained sheet with a scanning electron microscope (SEM).
As a result of observation, a hole of about 1 μm was observed on the surface,
In the cross section, a mesh-like (mesh size of 3 to 5 μm) PPS could be observed. Also, a mixed and dispersed aqueous solution of 10 μm silica particles and 0.5 μm latex was prepared,
As a result of examining the effect of the sheet obtained by removing the SF as a filter, the sheet had filtering ability for latex and silica.

(Comparative Example 5) PPS and polypropylene having the same melt viscosity as PPS (“Mitsubishi Polypro PY220” manufactured by Mitsubishi Yuka Co., Ltd., complex viscosity = 400)
Pa · sec) and (mixing weight ratio = 1: 1) at 300 ° C.
After melt kneading at a linear velocity of 0.7 m / sec on the outer periphery of the screw, injection was performed at a velocity of 20 cm / sec to obtain a plate-like molded product.

With respect to the plate-like molded product thus obtained,
As in Example 1, as a result of observing the fractured cross section with a scanning electron microscope (SEM), no continuous phase structure was observed and a sea-island structure was formed.

(Comparative Example 6) PPS, polyethylene terephthalate (“Mitsui PET J-125”, manufactured by Mitsui Pet Resin Co., Ltd., complex viscosity = 50 Pa · sec) having the same melt viscosity as PPS (mixed weight) Ratio = 1: 1)
After melt kneading at 300 ° C. at a linear velocity of 0.7 m / sec on the outer periphery of the screw, injection was performed at a speed of 20 cm / sec to obtain a plate-like molded product.

With respect to the plate-like molded product thus obtained,
As in Example 1, as a result of observing the fractured cross section with a scanning electron microscope (SEM), no continuous phase structure was observed and a sea-island structure was formed.

[0076]

According to the process for producing a PPS resin composition of the present invention, it is possible to obtain a composition or a molded article having a continuous phase structure in which both compounded phases are continuously connected. The composition having such a structure is superior in impact resistance, breaking strength, breaking elongation, and the like, as compared with a conventional composition having a sea-island structure. Further, since a continuous phase structure is formed, a PPS porous mat excellent in heat resistance and chemical resistance can be obtained by removing a resin other than PPS.

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Claims (6)

[Claims] (1) Polyphenylene sulfide 30
The linear velocity at the outer peripheral portion of a screw used for melting and kneading 70 to 30% by weight of a thermoplastic resin selected from the group consisting of polycarbonate, polysulfone and polyether ketone (2) is 0.3 m / sec or more. A method for producing a polyphenylene sulfide resin composition having a structure in which each compounded resin is continuously connected, which is characterized by melt-kneading at a rotation speed. 2. The method for producing a polyphenylene sulfide resin composition according to claim 1, wherein the thermoplastic resin (2) is polycarbonate or polysulfone. 3. A structure in which each of the blended resins is continuously connected, wherein the polyphenylene sulfide resin composition obtained by the production method according to claim 1 is injection-molded at a speed of 5 cm / sec or more. A method for producing a molded article comprising a polyphenylene sulfide resin composition having 4. The method according to claim 3, wherein the thermoplastic resin (2) is polycarbonate or polysulfone. 4. The method according to claim 3, wherein the molded resin is a polyphenylene sulfide resin composition having a structure in which each of the blended resins is continuously connected. 5. A method for producing a mat-like material comprising polyphenylene sulfide, wherein polycarbonate and polysulfone are removed from a molded product obtained by the production method according to claim 4 using an organic solvent. 6. The polyphenylene sulfide resin composition obtained by the production method according to claim 2 and having a structure in which the blended resins are continuously connected, has a draft ratio of 2 to 6.
20. A method for producing a polyphenylene sulfide fibrous material having a fiber diameter of 1 μm or less, wherein the polycarbonate and the polysulfone are removed using an organic solvent after melt-spinning in the range of 20.