# US 11,306,204 B2 · Polyphenylene sulfide resin composition, method of producing same, and molded article

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- Number: US 11,306,204 B2
- Document ID: US11306204B2
- Status: Granted
- Kind: B2
- Application number: 16/759,943
- Filed: 2018-11-02
- Published: 2021-06-17
- Granted: 2022-04-19
- Earliest claimed: 2017-11-10
- Assignees: Toray Industries, Inc.
- Applicants: Toray Industries, Inc.
- Inventors: Gen Noguchi; Hisashi Yamanoue; Kei Saito
- Web page: https://patentgrep.com/patent/US11306204B2

## CPC

- B29B 7/845: {Venting, degassing or removing evaporated components in devices with rotary stirrers}
- C08L 81/02: Polythioethers; Polythioether-ethers
- B29B 7/002: {Methods (chemical aspects C08J3/00)}
- B29B 7/48: with intermeshing devices, e.g. screws
- B29B 7/726: {Measuring properties of mixture, e.g. temperature or density (B29B7/724 takes precedence)}
- B29B 7/728: {Measuring data of the driving system, e.g. torque, speed, power, vibration (B29B7/724 takes precedence)}
- B29B 7/82: Heating or cooling
- B29B 7/86: for working at sub- or superatmospheric pressure {(B01F33/70 takes precedence)}
- B29B 7/90: Fillers or reinforcements {, e.g. fibres}
- B29C 48/022: {characterised by the choice of material}
- B29C 48/40: using two or more parallel screws {or at least two parallel non-intermeshing screws}, e.g. twin screw extruders
- B29C 48/625: characterised by the ratio of the threaded length of the screw to its outside diameter [L/D ratio]
- B29C 48/92: Measuring, controlling or regulating
- C08J 3/12: Powdering or granulating
- C08J 3/201: {Pre-melted polymers}
- C08J 3/203: {Solid polymers with solid and/or liquid additives}
- C08K 5/5415: containing at least one Si—O bond
- C08K 5/5435: containing oxygen in a ring
- C08K 5/544: containing nitrogen
- C08L 53/025: {modified}
- F16L 11/04: made of rubber or flexible plastics
- B29B 7/183: {having a casing closely surrounding the rotors, e.g. of Banbury type (with single shaft B29B7/125)}
- B29B 7/42: with screw or helix
- B29B 7/88: Adding charges {, i.e. additives}
- B29C 2948/92542: Energy, power, electric current or voltage
- B29C 2948/92876: Feeding, melting, plasticising or pumping zones, e.g. the melt itself
- B29K 2081/04: {Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof}
- C08J 2381/04: Polysulfides
- C08J 2453/02: of vinyl aromatic monomers and conjugated dienes
- C08L 53/02: of vinyl-aromatic monomers and conjugated dienes
- 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
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (A); an aromatic vinyl compound block copolymer (B) containing at least one functional group selected from the group consisting of a carboxyl group, an acid anhydride group, a hydroxyl group, an amino group, an epoxy group and an isocyanate group; and an alkoxysilane compound (C) containing at least one functional group selected from the group consisting of an epoxy group, an amino group and an isocyanate group; wherein a phase structure of the polyphenylene sulfide resin composition is a sea-island structure in which the polyphenylene sulfide resin (A) forms a sea phase, and the aromatic vinyl compound block copolymer (B) forms an island phase dispersed in a number average dispersed particle size of 1,000 nm or less.

## Claims

### Claim 1

A method of producing the polyphenylene sulfide resin composition which comprises:
99.5 to 51 parts by weight of a polyphenylene sulfide resin (A);
0.5 to 49 parts by weight of an aromatic vinyl compound block copolymer (B) containing at least one functional group selected from the group consisting of a carboxyl group, an acid anhydride group, a hydroxyl group, an amino group, an epoxy group and an isocyanate group; and
0.1 to 2.0 parts by weight, with respect to 100 parts by weight of the total amount of said polyphenylene sulfide resin (A) and said aromatic vinyl compound block copolymer (B), of an alkoxy silane compound (C) containing at least one functional group selected from the group consisting of an epoxy group, an amino group and an isocyanate group;
wherein a phase structure of said polyphenylene sulfide resin composition is a sea-island structure in which said polyphenylene sulfide resin (A) forms a sea phase, and said aromatic vinyl compound block copolymer (B) forms an island phase dispersed in a number average dispersed particle size of 1,000 nm or less,
the method comprising:
performing melt-kneading using a twin screw extruder having a ratio L/D of screw length L to screw diameter D of 10 or more, at a melt-kneading energy E (kWh/kg), represented by equation (2), of 0.15 kWh/kg or more and 0.50 kWh/kg or less:
E={(A/B)×C}/F (2)
wherein A represents a screw rotation speed (rpm) of said twin screw extruder during the melt-kneading; B represents a maximum screw rotation speed (rpm) of said twin screw extruder; C represents an output (kW) of a screw drive motor during the melt-kneading; and F represents a discharge amount (kg/h) of a molten resin during the melt-kneading,
wherein said twin screw extruder includes:
a cylinder;
a main feed port provided to said cylinder; and
a side feed port provided on a downstream side of said main feed port in an extrusion direction;
wherein said aromatic vinyl compound block copolymer (B) is fed from said side feed port, and
80% to 98% by weight of the total amount of said aromatic vinyl compound block copolymer (B) is fed from said side feed port, and 2 to 20% by weight of said aromatic vinyl compound block copolymer (B) is fed from said main feed port.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the screw rotation speed of said twin screw extruder is 300 rpm or more.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the resin temperature at a die exit of said twin screw extruder is 400° C. or lower.