Polyarylene sulphide resin composition and process for producing the same

Abstract: A polyarylene sulphide composition having improved mechanical properties and excellent surface appearance when molded comprises (A) 99 to 20 parts by weight of polyarylene sulphide, (B) 1 to 80 parts by weight of a polyamide and (C) 0.01 to 5 parts by weight, based on 100 parts by weight of (A) and (B) in total, of an alkoxysilane. It may further comprise (D) up to 400 parts by weight of a filler in the form of fiber, particles or plates. It can be produced by blending (A), (B) (C) and (D) with one another and melt-kneading the blend for at least 30 seconds while heated.

Description: The present invention relates to an improved polyarylene sulphide resin composition and a process for producing the same. In particular, the invention relates to a polyarylene sulphide resin composition having improved impact resistance and ductility and an excellent surface appearance when molded. Flame-retarding thermoplastic resins having high thermal resistance and chemical resistance are required as materials for the components of electric and electronic appliances, automobiles and chemical apparatus. Polyarylene sulphide resins represented by polyphenylene sulphide are among the resins satisfying these requirements and because of their good properties and low cost the demand for them is expanding. However, these resins have serious defects in that they have a low ductility and are brittle. It is known that the properties required of engineering plastics, such as strength, rigidity, tenacity and thermal resistance, can be considerably improved by incorporating a fibrous reinforcing material such as a glass fiber or carbon fiber into the resins. However, even after incorporation of the fibrous reinforcing material into polyarylene sulphide resins, they are still more brittle than other engineering plastics such as nylon or polyacetal. Thus, despite their other excellent properties, their use for various purposes is limited because of their insufficient tenacity. The following processes have been proposed to solve this problem: (1) a process wherein an α-olefin copolymer graft-copolymerized with 10% by weight or less of an unsaturated carboxylic acid or its anhydride and an epoxy resin are incorporated in the polyarylene sulphide resin (see Japanese Laid-open Patent Specification No. 207921/1984), (2) a process wherein an olefin copolymer comprising an α-olefin and a glycidyl ester of an α,β-unsaturated acid is incorporated (see Japanese Laid-Open Patent Specification No. 189166/1984), and (3) a process wherein a polyamide resin and an epoxy resin are incorporated (see Japanese Laid-Open Patent Specification No. 155462/1984). However, none of these processes represents a complete solution to the problem. In the above-described processes (1) and (2), the polyarylene sulphide resin is combined with an olefinic copolymer having an ester bond to improve the resin's tenacity. However, according to the follow-up tests of the inventors, the olefinic copolymer is decomposed in the molding step and thus makes the tenacity of the molding insufficient, since the molding temperature of the polyarylene sulphide resin is as high as 300 to 320°C. According to the same tests, the above-described process (3) is unsatisfactory in practice, since bleeding is observed on the surface of the molding, the state of the surface is bad and the melt flow stability of the composition is quite low. After intensive investigations made for the purpose of improving the tenacity of the polyarylene sulphide resin composition and the appearance of the surface of the molding, the inventors have noted reactive terminals of a polyarylene sulphide and a polyamide resin having a high tenacity. The inventors made further investigations for the purpose of finding a reactive substance which reacts with both resins under such conditions that the main chain thereof is not cleaved. As a result the inventors have found that when a silane compound having an alkoxyl group in the molecule is kneaded with the polyarylene sulphide resin and a polyamide elastomer resin (which optionally includes a polyamide resin) at a specified temperature for a specified time, a practicable molding material can be provided having a remarkably high tenacity and capable of forming a molding with an excellent surface appearance. The present invention has been completed on the basis of this finding. According to the present invention there is provided a polyarylene sulphide composition comprising (A) 99 to 20 parts by weight of polyarylene sulphide, (B) 1 to 80 parts by weight of a polyamide which consists of (B') 1 to 80 parts by weight of a polyamide elastomer and (B") up to 79 parts by weight of a polyamide, and (C) 0.01 to 5 parts by weight, based on 100 parts by weight of (A) and (B) in total, of an alkoxysilane. The composition of the invention may further comprise (D) up to 400 parts by weight (based on 100 parts in total of (A), (B) and (C)) of a filler in the form of fiber, particles or plates, or a mixture thereof. The invention also provides a process for producing the above-described polyarylene sulphide resin composition which comprises blending (A), (B), (C) and, if included, (D) with one another and melt-kneading the blend for at least 30 seconds while heated. The alkoxysilane of the embodiment (2) is preferably selected from vinylalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes, mercaptoalkoxysilanes and arylalkoxysilanes. The polyarylene sulphide resin used as the component (A) of the composition of the present invention mainly comprises recurring units --(-Ar-S-)-- wherein Ar represents an arylene group. The arylene groups (-Ar-) include p-phenylene group m-phenylene group o-phenylene group substituted phenylene groups wherein R represents an alkyl group, preferably a C 1 to C 5 alkyl group, or a phenyl group and n represents an integer of 1 to 4, p,p'-diphenylene sulphone group p,p'-biphenylene group p,p'-diphenylene ether group p,p'-diphenylenecarbonyl group and naphthalene group A polymer comprising only one kind of the recurring units selected from among the arylene sulphide groups having the above-described arylene groups, namely a homopolymer, is usable and a copolymer comprising two or more kinds of the recurring units is sometimes preferred from the viewpoint of the processability of the composition. As the homopolymer, a substantially linear homopolymer comprising a p-phenylene sulphide group as the recurring unit, wherein the arylene group is a p-phenylene group, is particularly preferred. For forming the copolymer, a combination of two or more kinds of the arylene sulphide groups comprising the above-described arylene groups can be used. Among them, a combination comprising a p-phenylene sulphide group with a m-phenylene sulphide group is particularly preferred. Among them, substantially linear copolymers comprising at least 50 molar %, preferably at least 60 molar % and more preferably at least 70 molar %, of p-phenylene sulphide groups are suitable from the viewpoint of the properties such as thermal resistance, moldability and mechanical properties. The amount of the m-phenylene sulphide group is suitably 5 to 50 molar %, particularly 10 to 25 molar %. As for the arrangement of the recurring units, a block arrangement (as described in, for example, Japanese Laid-Open Patent Specification No. 14228/1986) is preferred, being better than a random arrangement with respect to the thermal resistance and mechanical properties, although the workability is almost equal in both cases. As the polyarylene sulphide resin component (A) of the present invention, there can be used a polymer having an increased melt viscosity and an improved moldability produced by curing by oxidative cross-linking or thermal cross-linking of the above-described polymer or a polymer having a substantially linear structure obtained by poly-condensation of monomers mainly comprising a bifunctional monomer. The properties of a molding prepared from the latter polymer having a substantially linear structure are usually better than those prepared from the former polymer. As the polyarylene sulphide resin (A) of the present invention, a blended resin prepared by blending the above-described linear polymer with a cross-linked polyarylene sulphide resin which is in gel form when it is melted and which is produced by polymerizing a monomer having three or more functional groups with other monomers is preferably used in addition to the above-described polymers. The polyamide elastomer resin used as the component (B') in the present invention is a polyamide block copolymer comprising a polyamide hard segment and another soft segment and having a Young's modulus in flexure of 10,000 kgf/cm 2 (50% relative humidity, 23°C) or less. Typical examples of the soft segments of the elastomer include polyalkylene oxides, particularly those having a molecular weight of 400 to 60,000 and 2 to 6 carbon atoms in the alkylene group. Various processes have been reported for the synthesis of such a polyamide elastomer. Usually a process comprising two steps, i.e. a step of forming a nylon oligomer and a step of polymerization by esterification is employed. The polyamide components herein usable as the hard segment include polyamide 6, polyamide 66, polyamide 6.12, polyamide 11 and polyamide 12. Polyether components herein usable as the soft segment include polyoxyethylene glycol, polyoxypropylene glycol and polyoxytetramethylene glycol. The polyamide elastomer resin (B') preferably has a water content below a predetermined limit and is desirably dried prior to use. The amount of the polyamide elastomer resin (B') varies depending on the use thereof. Preferably it is 1 to 80 parts by weight for 99 to 20 parts by weight of the polyarylene sulphide resin (A). More preferably it is 5 to 80 parts by weight for 95 to 20 parts by weight of the polyarylene sulphide resin. When it is less than 1 part by weight, no sufficient effect of improving the tenacity of the resin composition can be obtained. A polyamide resin (B") can be used in combination with the polyamide elastomer resin (B'). The polyamide resin (B") is suitably a polyamide having a Young's modulus in flexure of at least 10,000 kgf/cm 2 (50% relative humidity, 23°C). It has a high affinity for the polyamide elastomer, it regulates mechanical properties, particularly, elasticity, of the whole composition and it is less expensive than the polyamide elastomer resin. Therefore, it is preferably used for forming a molding having excellent mechanical strength and thermal resistance at a low cost. However, an excess amount thereof is not preferred, since it impairs the hygroscopicity. The polyamide resins usable in the present invention include various known ones such as polyamide resins produced by the polycondensation of a dicarboxylic acid, e.g. oxalic, adipic, suberic, sebacic, terephthalic, isophthalic or 1,4-cyclohexyldicarboxylic acid with a diamine, e.g. ethylenediamine, pentamethylenediamine, hexamethylenediamine, decamethylenediamine, 1,4-cyclohexyldiamine or m-xylylenediamine; polyamide resins produced by the polymerization of a cyclic lactam, e.g. caprolactam or laurolactam; or polyamide resins obtained by copolymerizing with a cyclic lactam with a salt of a dicarboxylic acid with a diamine. The preferred polyamide resins are nylon 6, nylon 66, nylon 6.10, nylon 66/6.10, nylon 6/66 and nylon 12. Nylon 6 and nylon 66 are particularly preferred. The polyamide resin to be used preferably has a water content below a predetermined limit and, therefore, it is desirably dried prior to use. The combined amount of the polyamide elastomer and polyamide resin (B) used in the present invention is 1 to 80% by weight based on the total of the components (A) and (B). If the amount of the component (B) is insufficient, the effect of improving the tenacity is unsatisfactory. If the amount is in excess of 80% the advantages of the polyarylene sulphide resin (A) are impaired. The components (C) usable in the present invention include vinylalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes mercaptoalkoxysilanes and allylalkoxysilanes. They may be used either singly or in combination of two or more of them. The vinylalkoxy-silanes include vinyltriethoxysilane, vinyltrimethoxysilane and vinyltris(β-methoxyethoxy)silane. The epoxyalkoxysilanes include γ-glycidoxypropyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane and γ-glycidoxypropyltriethoxysilane. The aminoalkoxysilanes include γ-aminopropyltrimethoxysilane, γ-aminopropylmethyldiethoxysilane, N-(β-aminoethyl)-γ-aminopropyltrimethoxysilane and N-phenyl-γ-aminopropyltrimethoxysilane. The mercaptoalkoxysilanes include γ-mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane. The allylalkoxysilanes include γ-diallylaminopropyltrimethoxysilane, γ-allylaminopropyltrimethoxysilane and γ-allylthiopropyltrimethoxysilane. The amount of the alkoxysilane compound used as the component (C) is 0.01 to 5 parts by weight, preferably 0.5 to 3 parts by weight, for 100 parts by weight of the total of the polyarylene sulphide resin [component (A)] and polyamide elastomer and polyamide resin [component (B)]. The added amount of the alkoxysilane compound (C) varies depending on the kind thereof and the intended use of the composition. When it is insufficient, the effect of improving the tenacity is insufficient and, on the contrary, when it is excess, the melt viscosity is increased excessively to cause defects in the molding operation. Although the filler used as the component (D) is not essential, it is preferably used in order to give a molding having excellent properties such as mechanical strength, thermal resistance, dimensional stability and electrical properties. The amount of the inorganic filler is preferably not greater than 400 parts by weight for 100 parts by weight of the total of the resin components (A), (B) and (C). When the amount exceeds 400 parts by weight, the moldability and tenacity are unfavorably impaired. It is particularly preferably not greater than 250 parts by weight. The selected filler is fibrous, particulate or platy filler depending on the required duty. The fibrous fillers include inorganic fibrous substances such as glass, asbestos, carbon, silica, silica/alumina, zirconia, boron nitride, silicon nitride, boron and potassium titanate fibers, and metallic fibers such as stainless steel, aluminium, titanium, copper and brass fibers. Among them, a typical fibrous filler is glass fiber or carbon fiber. Furthermore high-melting organic fibrous substances such as polyamide, fluororesin and acrylic resin are also usable. The particulate fillers include carbon black, silica, quartz powder, glass beads, glass powder, silicates such as calcium silicate, aluminium silicate, kaolin, talc, clay, diatomaceous earth and wollastonite, metal oxides such as iron oxide, titanium oxide and alumina, metal carbonates such as calcium carbonate and magnesium carbonate, metal sulphates such as calcium sulphate and barium sulphate, silicon carbide, silicon nitride, boron nitride and various metal powders. The platy fillers include mica, glass flakes and various metal foils. These inorganic fillers may be used either singly or in combination of two or more of them. The combination of the fibrous filler, particularly glass fiber or carbon fiber, with a particulate or platy filler is particularly preferred for obtaining excellent mechanical strength, dimensional accuracy and electrical properties. The composition of the present invention may contain one or more antioxidants, thermal stabilizers, lubricants, nucleating agents, ultraviolet absorbers, colorants, releasing agents and other ordinary additives so far as the object of the present invention is not inhibited. These additives can be incorporated into the resin composition during the above-described melt kneading treatment or in any other step. The compositions of the present invention can be produced by various known processes. It is indispensable, however, that at least the components (A), (B) [i.e. (B') and (B")] and (C) are kneaded together in a molten state for at least 30 sec. In particular, for example, the components (A), (B) and (C) and, if necessary, component (D) and other components are homogeneously mixed with a mixer such as a tumbler or a Henschel mixer before the mixture is fed into a single-screw or twin-screw extruder and melt-kneaded to form pellets. In this step, preferably a part or the whole of the components (A) and (B) are pulverized, a part of the resin is first homogeneously mixed with the component (C) in a blender and the obtained mixture is further mixed with the rest and melted. The component (D) may be added during or after the melting step. It is particularly preferred to add the component (D) after the polymeric components have been melt-kneaded and reacted with the component (C) in order to obtain a significant effect in improving the tenacity. The treatment temperature is higher than the melting point of the resin components by 5° to 100°C, particularly preferably by 10° to 60°C. An excessively high temperature causes decomposition and abnormal reactions. The treatment time which varies depending on the treatment temperature and the kind and amount of the silane compound ranges from 30 sec to 15 min, preferably 1 to 10 min. Although a detailed mechanism of the effect of the alkoxysilane compound (C) of the present invention has not yet been fully elucidated, it is supposed that the polyarylene sulphide molecule is bonded to the polyamide molecule by means of the silane compound to improve the compatibility of the components (A) and (B) with each other. This mechanism was confirmed by the fact that the viscosity is increased by the melting treatment conducted in the presence of the component (C) and also by electron-microscopic observation of the cross-sectional phase structure of the molding prepared from the composition. According to the process of the present invention, the polyamide resin can be dispersed in the form of minute particles (1µm or less), while it is dispersed in the form of very coarse particles (10µm or more) in the absence of the silane compound (C). It will be apparent from the above description and the following Examples that the resin components are quite finely dispersed in the polyarylene sulphide resin composition of the present invention and that the composition has the following effects: (1) the molding produced from the composition has remarkably improved mechanical properties such as tensile elongation and impact resistance, (2) the mechanical properties are well-balanced with the thermal resistance, and (3) the molding has an excellent appearance. (4) the resin composition can be produced at a low cost, since the additives are inexpensive and can be easily extrusion-kneaded. The following non-limiting Examples will further illustrate the present invention. COMPARATIVE EXAMPLES 1 TO 7. 40 parts by weight of nylon 66 was added to 60 parts by weight of a polyphenylene sulphide polymer (m.p.: 285°; melt viscosity: about 500 P, determined at a shear rate of 1200 sec -1 at 310°). Further γ-aminopropyltriethoxysilane and, if necessary, a glass fiber (chopped strands having a diameter of 10µm and a length of 3mm) in amounts specified in Table 1 were added thereto. They were premixed with a Henschel mixer for 5 min. The mixture was melt-kneaded with an extruder at a cylinder temperature of 310°C to prepare pellets of the polyphenylene sulphide resin composition. Then the pellets were shaped into ASTM test pieces with an injection molding machine at a cylinder temperature of 310°C and mold temperature of 150°C. The test pieces were subjected to tensile, impact and heat distortion tests. The appearance of the surface of the molding was macroscopically evaluated. The results are summarized in Table 1. COMPARATIVE EXAMPLES 8 TO 15. Nylon 66 was added to the same polyphenylene sulphide polymer as that used in the above-described Comparative Examples in a ratio specified in Table 2. Further γ-aminopropyltriethoxysilane and glass fiber in a ratio specified in Table 2 were added thereto and the same procedure as that of Comparative Examples 1 to 7 was repeated. The results are given in Table 2. COMPARATIVE EXAMPLES 14 TO 17. 40 parts by weight of nylon 6 was added to 60 parts by weight of the same polyphenylene sulphide polymer as that described above. Then aminopropyltriethoxysilane and glass fiber in amounts specified in Table 3 were added thereto. Then the same procedure as that of Comparative Examples 1 to 7 was repeated. The results are given in Table 3. COMPARATIVE EXAMPLES 18 TO 21. 40 parts by weight of nylon 12 was added to 60 parts by weight of the same polyphenylene sulphide polymer as that used in the above-described Comparative Examples. Then γ-aminopropyltriethoxysilane and glass fiber in amounts specified in Table 4 were added thereto. The same procedure as that of Comparative Examples 1 to 7 was repeated. The results are given in Table 4. COMPARATIVE EXAMPLES 22 AND 23. 40 parts by weight of nylon 66 was added to 60 parts by weight of the same polyphenylene sulphide polymer as that used in the above-described Comparative Examples. Then γ-glycidoxypropyltrimethoxysilane and glass fiber in amounts specified in Table 5 were added thereto. The same procedure as that of Comparative Examples 1 to 7 was repeated. The results are given in Table 5 together with those of Comparative Examples 1 and 6. COMPARATIVE EXAMPLES 24 AND 25. The same procedure as that of Comparative Examples 22 and 23 was repeated except that γ-glycidoxypropyltrimethoxysilane was replaced by γ-mercaptopropyltrimethoxysilane in amounts specified in Table 6. The results are given in Table 6 together with those of Comparative Examples 1 and 6. COMPARATIVE EXAMPLES 26 AND 27. The same procedure as that of Comparative Examples 22 and 23 was repeated except that γ-glycidoxypropyltrimethoxysilane was replaced with vinyltrimethoxysilane in amounts specified in Table 7. The results are given in Table 7 together with those of Comparative Examples 1 and 6. EXAMPLES 1 TO 5 AND COMPARATIVE EXAMPLES 28 AND 29. 20 parts by weight of a polyamide elastomer (trade name: DAIAMID E 62, a product of Daicel-Huls Ltd.* ) (see the following Note 1) was added to 80 parts by weight of a polyphenylene sulphide polymer (m.p.: 285°C; melt viscosity: about 500 P, determined at a shear rate of 1200 sec -1 at 310°). Further γ-aminopropyltriethoxysilane and, if necessary, a glass fiber (chopped strands having a diameter of 10µm and a length of 3mm) in amounts specified in Table 8 were added thereto. They were premixed with a Henschel mixer for 5 min. The mixture was melt-kneaded with an extruder at a cylinder temperature of 310°C to prepare pellets of the polyphenylene sulphide resin composition. Then the pellets were shaped into ASTM test pieces with an injection molding machine at a cylinder temperature of 310°C and mold temperature of 150°C. The test pieces were subjected to tensile, impact and distortion tests. The appearance of the surface of the molding was macroscopically evaluated. The results are summarized in Table 8. EXAMPLES 6 TO 9 AND COMPARATIVE EXAMPLES 30 AND 31. DAIAMID E 62™ was added to the same polyphenylene sulphide polymer as that used in the above-described Examples and Comparative Examples in a ratio specified in Table 9. Further γ-aminopropyltriethoxysilane and glass fiber in a ratio specified in Table 9 were added thereto and the same procedure as that of Examples 1 to 5 was repeated. The results are given in Table 9 EXAMPLES 10 TO 17. 20 parts by weight of a polyamide elastomer (DAIAMID E 62™) was added to 80 parts by weight of the same polyphenylene sulphide polymer as that described above. Then γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, vinyltrimethoxysilane or γ-diallylaminopropyltrimethoxysilane and glass fiber in amounts specified in Table 10 were added thereto. Then the same procedure as that of Examples 1 to 5 was repeated. The results are given in Table 10. EXAMPLES 18 TO 22 AND COMPARATIVE EXAMPLES 32 AND 33. A polyamide elastomer (DAIAMID E 62™) and a polyamide (PA) 66 in amounts specified in Table 11 were added to 60 parts by weight of the same polyphenylene sulphide polymer as that described above. 2 parts by weight of γ-aminopropyltriethoxysilane and, if necessary, glass fiber in an amount specified in Table 11 were added to 100 parts by weight of the total mixture obtained as described above. Then the same procedure as that of Examples 1 to 5 was repeated. The results are given in Table 11. EXAMPLES 23 TO 32 AND COMPARATIVE EXAMPLES 34 AND 35. 20 parts by weight of a polyamide elastomer (trade name: DAIAMID E 40™, a product of Daicel-Huls Ltd* ) (see the following Note 2) was added to 80 parts by weight of the above-described polyphenylene sulphide polymer. Then γ-aminopropyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, vinyltrimethoxysilane or γ-diallylaminopropyltrimethoxysilane and, if necessary, glass fiber in amounts specified in Table 12 were added thereto. Then the same procedure as that of Examples 1 to 5 was repeated. The results are given in Table 12 Comparative Example No 14 15 16 17 PROPORTION Polyphenylene sulfide resin parts by weight 60 60 60 60 Nylon 6 Resin 40 40 40 40 γ-aminopropyltriethoxysilane - 2 - 2 Glass fiber - - 67 67 PROPERTIES Tensile strength (kgf/cm 2 ) 620 830 1450 2110 Tensile elongation (%) 8 63 1.8 9 Izod impact strength Notched Kg.cm/cm 2.8 7.4 6.2 13.5 Izod impact strength Unnotched Kg.cm/cm 21 106 31 68 Heat distortion Temperature (°C) (18.6 kg load) 109 107 247 247 Appearance of molding bad good bad good Comparative Example No 18 19 20 21 PROPORTION Polyphenylene sulfide resin parts by weight 60 60 60 60 Nylon 12 Resin 40 40 40 40 γ-aminopropyltriethoxysilane - 2 - 2 Glass fiber - - 67 67 PROPERTIES Tensile strength (kgf/cm2) 560 710 1370 2000 Tensile elongation (%) 3.1 48 1.4 7.4 Izod impact strength Notched Kg.cm/cm 1.8 5.3 5.4 12.1 Izod impact strength Unnotched Kg.cm/cm 15 71 28 53 Heat distortion Temperature (°C) (18.6 kg load) 82 80 237 236 Appearance of molding bad good bad good Comparative Example No 1 22 6 23 PROPORTION Polyphenylene sulfide resin parts by weight 60 60 60 60 Nylon 66 Resin 40 40 40 40 γ-glycidylpropyltrimethoxysilane - 2 - 2 Glass fiber - - 67 67 PROPERTIES Tensile strength (kgf/cm2) 650 870 1550 2440 Tensile elongation (%) 6 56 1.4 7.1 Izod impact strength Notched Kg.cm/cm 2.2 6.2 5.7 13.2 Izod impact strength Unnotched Kg.cm/cm 15 98 27 64 Heat distortion Temperature (°C) (18.6 kg load) 114 107 253 252 Appearance of molding bad good bad good Comparative Example No 1 24 6 25 PROPORTION Polyphenylene sulfide resin parts by weight 60 60 60 60 Nylon 66 Resin 40 40 40 40 γ-mercaptopropyltrimethoxysilane - 2 - 2 Glass fiber - - 67 67 PROPERTIES Tensile strength (kgf/cm2) 650 810 1550 2280 Tensile elongation (%) 6 44 1.4 5.6 Izod impact strength Notched Kg.cm/cm 2.2 4.7 5.7 11.4 Izod impact strength Unnotched Kg.cm/cm 15 72 27 48 Heat distortion Temperature (°C) (18.6 kg load) 114 109 253 255 Appearance of molding bad good bad good Comparative Example No 1 26 6 27 PROPORTION Polyphenylene sulfide resin parts by weight 60 60 60 60 Nylon 66 Resin 40 40 40 40 vinyltrimethoxysilane - 2 - 2 Glass fiber - - 67 67 PROPERTIES Tensile strength (kgf/cm2) 650 830 1550 2300 Tensile elongation (%) 6 47 1.4 5.8 Izod impact strength Notched Kg.cm/cm 2.2 5.0 5.7 12.2 Izod impact strength Unnotched Kg.cm/cm 15 78 27 54 Heat distortion Temperature (°C) (18.6 kg load) 114 108 253 254 Appearance of molding bad good bad good

Claims: A polyarylene sulphide composition comprising (A) 99 to 20 parts by weight of polyarylene sulphide, (B) 1 to 80 parts by weight of a polyamide which consists of (B') 1 to 80 parts by weight of a polyamide elastomer and (B") up to 79 parts by weight of a polyamide, and (C) 0.01 to 5 parts by weight, based on 100 parts by weight of (A) and (B) in total, of an alkoxysilane. A polyarylene sulphide composition as claimed in claim 1, in which the alkoxysilane is selected from vinylalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes, mercaptoalkoxysilanes and arylalkoxysilanes. A polyarylene sulphide composition as claimed in any preceding claim, in which the polyarylene sulphide (A) is a substantially linear homopolymer comprising a p-phenylene sulphide group as the recurring unit. A polyarylene sulphide composition as claimed in any one of claims 1 to 2, in which the polyarylene sulphide (A) is a copolymer of p-phenylene sulphide groups with m-phenylene sulphide groups. A polyarylene sulphide composition as claimed in any preceding claim, in which the amount of the alkoxysilane compound (C) is 0.5 to 3 parts by weight, based on 100 parts by weight of the total of the polyarylene sulphide resin [component (A)] and polyamide resin(s) [component (B)]. A polyarylene sulphide composition as claimed in any preceding claim, which further comprises (D) up to 400 parts by weight [based on 100 parts in total of (A), (B) and (C)] of a filler in the form of fiber, particles or plates, or a mixture thereof. A polyarylene sulphide composition as claimed in claim 6, in which the amount of the filler (D) is not more than 250 parts by weight, based on 100 parts in total of (A), (B) and (C)]. A polyarylene sulphide composition as claimed in any preceding claim, in which said polyamide elastomer resin is a block copolymer comprising a hard polyamide segment and another soft segment, and having a Young's modulus in flexure of 10,000 kgf/cm 2 (50% relative humidity, 23°C) or less. A polyarylene sulphide resin composition as claimed in claim 8, wherein the polyamide hard segment is selected from polyamide 6, polyamide 66, polyamide 6.12, polyamide 11 and polyamide 12. A polyarylene sulphide resin composition as claimed in claim 8 or 9, wherein the polyamide soft segment is a polyalkylene oxide having a molecular weight of 400 to 60,000 and comprising an alkylene group having 2 to 6 carbon atoms. A polyarylene sulphide resin composition as claimed in any preceding claim, wherein the polyamide is selected from nylon 6, nylon 66, nylon 6.10, nylon 66/6.10, nylon 6/66 and nylon 12. A process for producing a polyarylene sulphide resin composition as claimed in any preceding claim, which comprises blending (A), (B), (C) and, if included, (D) with one another and melt-kneading the blend for at least 30 seconds while heated.

Inventors: KUBOTA MASARU, NONAKA TOSHIFUMI, SANO HIROYUKI, SERIZAWA HAJIME, UOTA KATSUMI, KUBOTA, MASARU, NONAKA, TOSHIFUMI, SANO, HIROYUKI, SERIZAWA, HAJIME, UOTA, KATSUMI
Applicants: POLYPLASTICS CO, POLYPLASTICS CO. LTD.
Application year: 1990
Main classification: C08L81
IPC codes: C08K5, C08L77, C08L81