Method for reforming a liquid crystal resin composite

Abstract: The present invention relates to a method for reforming a composite resin having a high tensile strength and a high rigidity into a reformed molding product having an tensile strength and rigidity the same as those of a molding product from the original composite resin. The present invention comprises steps of: providing a molding product of a composite resin 10 of thermoplastic resin and liquid crystal polymer having a crystal transition point higher than a minimum moldable temperature of the thermoplastic resin; crushing said composite resin 10 into particles or pieses 14; heating said particles or pieses 14 at a temperature higher than the transition temperature of said liquid crystal polymer to obtain a molten composite resin 22 by using a injection forming apparatus 20; either (i) extruding said molten composite resin 22 at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a moldable composite material of a sheet form 24 or of a strand form 26; and forming the moldable composite material 24 or 26 into a molding product 32 in a given shape at a temperature lower than the transition temperature of the liquid crystal polymer, or (ii) extruding the molten composite resin 22 at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a molding product 32 in a given shape.

Description: The present invention relates to a method for reforming a liquid crystal resin composite. There has been known a conventional synthetic resin product provided with a high tensile strength and a high rigidity which comprises a composite resin of a thermal setting resin such as SMC (sheet mold compound) and RIM mixed with glass fiber or a thermal setting resin called stan bubble sheet mixed with a long glass fiber and molded into a given shape. Further, there has been also known a synthetic resin mixed with carbon fiber in the place of the above glass fiber. Furthermore, in Japanese Patent Publication (unexamined) No.320128/1989 there is disclosed a composite resin comprising a thermoplastic resin and a liquid crystal resin, which has no glass fiber or carbon fiber mixed therein and which has a high tensile strength and a high rigidity. This composite resin can be prepared by extruding a mixture of thermal plastic resin and liquid crystal polymer (liquid crystal resin) at a temperature higher than a transition temperature of the liquid crystal polymer under being extended to obtain strand materials, cutting the strand materials into a small piece of 1 to 40mm, subjecting the small pieces to an extrusion molding at a temperature lower than the transition temperature of the liquid crystal polymer. Recently, in view of a conservation of resources, it has been required to reform and reuse plastic products. The reformation of plastic products, however, must be carried out by crushing the plastic product into particles, heating the crushed particles into a molten state, and forming the molten composite resin into a molding product of a given shape or extruding the molten composite resin into a raw moldable material and forming the moldable material into a molding product in a given shape. In the case of reforming the synthesized resin having a high tensile strength and a high rigidity such as a fiber reinforced resin (FRP) having a reinforcing material such as glass fiber or carbon fiber mixed therein, the reinforcing fiber is cut into small pieces when the fiber reinforced resin is crushed. As a result, a reformed product is inferior in the tensile strength and rigidity when compared with the original molding product. Therefore, an object of the present invention is to provide a method for reforming the synthesized resin having a high tensile strength and a high rigidity into a molding product having the same tensile strength and rigidity as those of the original molding product. As a result of our study, we have found that a reformed liquid crystal composite is provided with substantially the same physical properties as that of the original liquid crystal composite when the composite product may be reformed by the method comprising steps of; crushing a used product of a composite resin of thermoplastic resin as a matrix material and liquid crystal polymer, as a reinforcing material, having a crystal transition temperature higher than a minimum moldable temperature of the thermoplastic resin into particles or pieces; extruding said crushed particles or pieces at a temperature higher than the transition temperature to obtain a raw moldable material; and forming the moldable material into a molding product in a given shape at a temperature lower than the transition temperature. Also, we have found that the same effects as the above can be obtained by reforming the crushed particles or pieces directly into a molding product of a given shape at a temperature higher than the transition temperature of the liquid crystal polymer. Accordingly, in a first aspect the present invention is to provide a method for reforming a composite resin of liquid crystal polymer and thermoplastic resin comprising steps of: providing a used product of a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition temperature higher than a minimum moldable temperature of the thermoplastic resin; crushing said used molding product of a composite resin into particles or pieces; heating said particles or pieces at a temperature higher than the transition temperature of said liquid crystal polymer to obtain a molten composite resin; extruding said molten composite resin at a temperature higher than the transition temperature of said liquid crystal polymer to obtain raw moldable materials; and forming the moldable material into a molding product in a given shape at a temperature lower than the transition temperature of the liquid crystal polymer. In a second aspect, the present invention is to provide a method for reforming a composite resin of liquid crystal polymer and thermoplastic resin comprising steps of: providing a used product of a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition temperature higher than a minimum moldable temperature of the thermoplastic resin; crushing said composite resin into particles or pieces; heating said particles or pieces at a temperature higher than the transition temperature of said liquid crystal polymer to obtain a molten composite resin of the thermoplastic resin and the liquid crystal polymer; extruding said molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a molding product of a given shape. In a third aspect, it is found that, even when a thermoplastic resin contains a liquid crystal polymer of a fiber form before crushing, it is possible to obtain a molding product having the tensile strength and rigidity the same as those of the molding product from the original composite resin. This can be achieved by heating the crushed particles or pieces of the used composite resin at a temperature higher than the transition temperature of the liquid crystal polymer and forming the heated composite resin into a molding product of a given shape. Therefore, the present invention is also to provide a method for reforming a used composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition point (temperature) higher than a minimum moldable temperature of the thermoplastic resin, wherein the liquid crystal polymer can be of a fiber form present in the thermoplastic resin. In a fourth aspect, in order to ensure the orientation of the liquid crystal polymer in an extrusion direction the present invention is to provide a method for reforming a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition point higher than a minimum moldable temperature of the thermoplastic resin, wherein the step of obtaining a raw moldable composite material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer is directed to a step of obtaining a raw molding material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. In a fifth aspect, in order to ensure the orientation of the liquid crystal polymer oriented in an extrusion direction, the present invention is to provide a method for reforming a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition point higher than a minimum moldable temperature of the thermoplastic resin, wherein the step of forming the molten composite resin into a molding product at a temperature higher than the transition temperature of the liquid crystal polymer is directed to a step of extrusion-forming the molten composite resin into a molding product of a given shape at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. In a sixth aspect, in order to obtain a moldable composite material of a strand form, the present invention also is to provide a method for reforming a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition point higher than a minimum moldable temperature of the thermoplastic resin, wherein the step of obtaining a raw moldable material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer or the step of obtaining a raw moldable material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer under being extended is directed to a step of forming the raw molding material of a strand form. In a seventh aspect, in order to obtain a raw moldable material of a sheet form, the present invention is to provide a method for reforming a composite resin of thermoplastic resin and liquid crystal polymer having a crystal transition point higher than a minimum moldable temperature of the thermoplastic resin , wherein the step of obtaining the moldable composite material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer or the step of obtaining a raw molding material by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer under being extended is directed to a step of forming the moldable composite material of a sheet form. In accordance with the constitution of the first aspect of the present invention, the first step is to crush a used molding product, made from a composite resin of a thermoplastic resin and a liquid crystal polymer having a crystal transition temperature higher than that of the thermoplastic resin. When the crushed particles or pieces are heated at a temperature higher than the transition temperature of the liquid crystal polymer, the thermoplastic resin and the liquid crystal polymer change from a solid state into a molten state. Next, the molten composite resin is extruded at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a raw moldable composite material. In the present invention, although the crushing process makes the liquid crystal polymer to be cut into crushed particles or pieces of a small size, the next melting process causes the crushed particles to be combined with each other. Therefore, the liquid crystal polymer in the combined particles or pieces is solidified in a manner to have an orientation structure wherein molecules are oriented in one direction. Accordingly, the raw moldable composite material thus obtained results in a tensile strength and a rigidity the same as those of the original composite resin. Next, the raw moldable composite material is formed into a molding product of a given shape at a temperature lower than the transition temperature of the liquid crystal. Therefore, the reformed molding product has the liquid crystal polymer of a molecular orientation structure kept therein. In accordance with the constitution of the second aspect of the present invention, the first step is to crush a used product made from a composite resin of a thermoplastic resin and a liquid crystal polymer having a crystal transition temperature higher than a minimum moldable temperature of the thermoplastic resin. When the crushed particles or pieces are heated at a temperature higher than the transition temperature of the liquid crystal polymer, the thermoplastic resin and the liquid crystal polymer change from a solid state to a molten state. Next, the molten composite resin is extruded at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a molding product of a given shape. Although the crushing process makes the liquid crystal polymer to be cut into crushed particles of a small size in a similar way to the above method, the melting process causes the crushed particles or pieces to be combined with each other. The liquid crystal polymer in the combined crushed particles or pieces is solidified in a manner to have an orientation structure wherein molecules are oriented in a one direction. Accordingly, the molding product thus obtained results in an tensile strength and a rigidity the same as those of the original composite resin. In accordance with the constitution of the third aspect of the present invention, the liquid crystal polymer of a fiber form is included in the composite resin before the crushing and is cut into crushed particles or pieces of a small size. However, the melting process causes the crushed particles or pieces to be combined with each other, so that the liquid crystal polymer in the combined particles or pieces is solidified in a manner to have an orientation structure. Accordingly, the raw moldable material thus obtained includes a liquid crystal polymer of a fiber form having a same length as that of the original liquid crystal polymer and results in a tensile strength and a rigidity the same as those of the original composite resin. In accordance with the constitution of the fourth aspect of the present invention, the composite resin is extruded at a temperature higher than the transition temperature of the liquid crystal under being extended to obtain a raw moldable material. Hence, the liquid crystal polymer in the raw moldable material is oriented sufficiently to an extrusion direction. In accordance with the constitution of the fifth aspect of the present invention, the composite resin is extruded at a temperature higher than the transition temperature of the liquid crystal under being extended to obtain a molding product of a given shape. Hence, the liquid crystal polymer in the raw moldable product is oriented sufficiently to an extrusion direction. In accordance with the constitution of the sixth aspect of the present invention, it is possible to obtain a raw moldable material of a strand form. Therefore, it is easy to carry out an injecting formation by cutting the raw moldable material into a pellet form. In accordance with the constitution of the seventh aspect of the present invention, it is possible to obtain a raw moldable material of a sheet form which makes it easy to carry out a pressing. Meanwhile, the used product to be reformed, may contain various contents of liquid crystal polymer. Therefore, when two or more kinds of the used product are provided in order to reform a product containing a desired content of the liquid crystal polymer, there may be added thereto a new thermoplastic resin compatible to the matrix thermoplastic resin and/or a new liquid crystal polymer. That is, in the case of Fig. 12(a) wherein molding is carried out only by use of the used products, a reformed product comes to have almost the same properties as that of the original product. Further, as shown in Fig. 12(b), in the case wherein an amount of the liquid crystal polymer (L) is added thereto, an improved property is provided with a reformed product when compared with the original product. On the other hand, in the case wherein an amount of the matrix thermoplastic resin (M) is added thereto, a lowered property is provided with a reformed product when compared with the original product. Furthermore, in the case of Fig. 12(c) a middle property between that of a high content product and that of a low content product may be provided with a reformed product by using a mixture of crushed powders having a low content of the liquid crystal polymer (L) and having a high content of L. Further, an additional new thermoplastic resin and/or new liquid crystal resin may be added to the above mixture to obtain a desired composition ratio of the thermoplastic resin (M) and the liquid crystal resin (L) as shown in Fig.12(d). Accordingly, in an eighth aspect, the present invention is to provide a method for reforming a composite resin according to the present invention, wherein in the step of heating the crushed particles or pieces into a molten composite material, the crushed particles or pieces comprise a mixture of used composite resins having different contents of the liquid crystal resin or a mixture of a used composite resin and a liquid crystal resin and/or a thermoplastic resin. These and other objects and features of the present invention will become clear from the following description taken in conjunction with the following description taken in conjunction with the preferred embodiments thereof with reference to the accompanying drawings throughout which like parts are designated by like reference numerals, and in which: Fig. 1 is a schematic view illustrating the working steps of the reforming a composite resin in accordance with some of the embodiment of the present invention; Fig. 2 is a schematic view illustrating the working steps of the reformation of the composite resin shown in Fig. 1; Fig. 3 is a schematic view illustrating a change of the thermoplastic resin and liquid crystal polymer contained in the composite resin which is subjected to the reformation process shown in Fig. 1; Fig. 4 is a graph showing a relationship between an amount of the liquid crystal polymer and a tensile strength of a molding product obtained by using PC/ABS as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 5 is a graph showing a relationship between an amount of the liquid crystal polymer and an tensile strength of a molding product obtained by using PC/ABS as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 6 is a graph showing a relationship between an amount of the liquid crystal polymer and a flowing length ratio of a molding product obtained by using PC/ABS as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 7 is a graph showing a relationship between an amount of the liquid crystal polymer and a tensile strength of a molding product obtained by using PC/PBT as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 8 is a graph showing a relationship between an amount of the liquid crystal polymer and a tensile strength of a molding product obtained by using PC/PBT as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 9 is a graph showing a relationship between an amount of the liquid crystal polymer and a flowing length ratio of a molding product obtained by using PC/PBT as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 10 is a graph showing a relationship between an amount of the liquid crystal polymer and a tensile strength of a molding product obtained by using modified PPO as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 11 is a graph showing a relationship between an amount of the liquid crystal polymer and a tensile strength of a molding product obtained by using modified PPO as a thermoplastic resin in the reforming process shown in Fig. 1; Fig. 12 is a graph showing a relationship between mixing examples and the resulting property variations. The following description will be directed to the preferred embodiments of the present invention with reference to Figs. 1 to 3. As shown in Fig. 1a, a first step is to provide a used molding product such as an automobile bonnet made of composite resin 10 comprising a thermoplastic resin and a liquid crystal polymer having a melting point higher than that of the thermoplastic resin. The composite resin 10 is crushed by a crusher 12 into particles or pieces 14. Next, the crushed particles or pieces 14 are supplied to a molten resin extrusion apparatus 20 and are heated in the molten resin extrusion apparatus 20 at a temperature higher than the transition temperature of the liquid crystal into a molten resin 22 comprising a thermoplastic resin and a liquid crystal polymer. The molten resin 22 is extruded at a temperature higher than the transition temperature of the liquid crystal under being extended and formed into a molding material 24 of a sheet form as shown in Fig. 1c or into a molding material 26 of a strand form as shown in Fig. 1d. Next, the molding material 24 of a sheet form is heated at a temperature lower than the transition temperature of the liquid crystal in a preheating apparatus 28 as shown in Fig. 2a and then is pressed into a given shape by a pressing apparatus 30 to obtain reformed molding product 32 such as an automobile bonnet as shown in Fig. 2c. In this case depending on the shape of the reformed molding product 32, it is possible to cut the molding material 26 of a strand form into small pieces 34, to supply the crushed particles or pieces 34 to an injection forming apparatus 36 and to form into a reformed molding product 32 by an injection method under being heated. In the above embodiment, the reformed molding product 32 is prepared by using only the crushed particles or pieces 14. However, it is possible to use the crushed particles or pieces 14 having new thermoplastic resin and new liquid crystal polymer added thereto. Fig. 3 is a schematic view illustrating the reforming process in which the thermoplastic resin and the liquid crystal polymer change in the state with the working steps. Fig. 3a shows a state of the crushed particles or pieces 14 in advance to the heating. Reference numerals 14a and 14b indicate the thermoplastic resin and the liquid crystal polymer of a solid state, respectively, as constituents of the crushed particles or pieces 14. Fig. 3c shows a state of a molten composite resin 22 which is obtained by heating the crushed particles or pieces 14 at a temperature higher than the transition temperature of the liquid crystal polymer 14b. The thermoplastic resin 14a and the liquid crystal polymer 14b as constituents of the crushed particles or pieces 14 are of a molten state (liquid state). Fig. 3b shows a state of the crushed particles or pieces 14 heated at a temperature lower than the transition temperature of the liquid crystal polymer or a state of the crushed particles or pieces 14 cooled the molten composite resin 22 to a temperature lower than the transition temperature of the liquid crystal polymer 14b. The thermoplastic resin 14a is of a liquid state (molten state) but the liquid crystal polymer 14b is in a solid state. Accordingly, it is necessary to reform the crushed particles or pieces 14 of a state shown in Fig. 3b into a reformed molding product of a given shape by a pressing apparatus or an injection forming apparatus. The following description will be directed to a tensile strength and a flowing ability of the reformed molding product obtained by using PC/ABS as a thermoplastic resin. A liquid crystal polymer as a starting material comprises VECTRA A950 ( polyester of aromatic group, the liquid crystal transition temperature is about 280°C) made by POLYPLASTIC CO., LTD. and a thermoplastic resin as a starting material comprises TECHNIACE-T105 made by SUMITOMO DOW LTD.. A composite resin is prepared by mixing the two materials mentioned above in a given mixing ratio. Next, the composite resin is subjected to a first extrusion formation. The extrusion formation is carried out in the following conditions: an extruding apparatus is a twin screw extruder (screw diameter of 36 mm) made by RESEARCH LABORATORY OF PLASTIC TECHNOLOGY; a resin temperature is 290°C; a screw rotation is 100 rpm; die diameter is 2 mm; shear rate is 1700sec -1 and a tensile ratio is 2 times. The composite resin is extruded into a first molding material of a strand form in a diameter of 1. 4mm. The first molding material is cut into a first pellet material of a 3 mm length. Next, the first pellet material is formed into a composite resin by an injection method. The injecting formation is carried out in the following conditions: The used injecting formation apparatus 220 Toh made by TOSHIBA MACHINE CO., LTD.; a die is of a test piece type; the resin temperature is 250°C. The flowing ability is tested by using the injecting formation apparatus mentioned above and a die of a spiral flow type (diameter of 6mm of a half circle form) at the resin temperature of 250°C at an injecting pressure of 1000Kg/cm 2 . The injected composite resin is crushed into pellets having a length of 3 to 4 mm by using a crusher V-360 made by HORAI IRON WORKS CO., LTD.. The pellets are extruded into reformation molding material of a strand form of 1. 4mm diameter. The reformation molding material of a strand form is cut into recycle used pellets of a length of 3 mm. The injection working condition is the same as that of the first extrusion formation. The first raw moldable material of a strand form and the recycle used pellets are subjected to a tensile test. The test is carried out by using a universal testing machine (AUTOGRAPh) made by SHIMADZU Co. at a tensile rate of 20 mm/min. Figs. 4 and 5 are graphs showing the relation between a tensile strength and a content of the liquid crystal polymer contained in the first molding material and recycle used moldable material, respectively. The liquid crystal polymer starts to be formed into a fiber form at a range higher than 2 to 4 % of the liquid crystal amount. It is found that the first moldable material and recycle used molding material show the tensile strength the same as each other at the all range of the liquid crystal polymer content. This indicates clearly that the recycle used moldable material is not impaired in the tensile strength of the reformed moldable product compared with the case using the original molding material. Fig. 6 is a graph showing a relation between a flow length ratio and the content amount of liquid crystal polymer. It is clear from Fig. 6 that a flowing ability is greatly decreased at a liquid crystal polymer content higher than 60 %. It is difficult to achieve a reformed molding product by using the molding material having a content of liquid crystal polymer higher than 60%. In connection with a case using PC/ABS as a thermoplastic resin, the content of liquid crystal polymer preferably ranges from 2 to 60 %. An electron microscopic observation (SEM) indicates that a large part of the liquid crystal polymer is of a powder form and a small part is of a fiber form at the liquid crystal content of 2 %. On the other hand, the liquid crystal polymer content ranging from 4 to 8 % results in a liquid crystal polymer of a fiber form. It is understood from the observation that the liquid crystal polymer content ranging from 2 to 4 % makes the liquid crystal polymer to be of a fiber form and accordingly, increases the tensile strength of the resultant product. The following description will be directed to a tensile strength and a flowing ability of a reformed molding product obtained by using PC/PBT as a thermoplastic resin. A liquid crystal polymer as a starting material comprises VECTRA A950 (polyester of aromatic group, the liquid crystal transition temperature is about 280°C) made by POLYPLASTIC CO. LTD. and a thermoplastic resin PC/PBT as a starting material comprises XENOY 1101 made by GE PLASTIC JAPAN LTD.. A composite resin is prepared by mixing the two reagents mentioned above in a given mixing ratio. Next, the composite resin is subjected to a first extrusion formation in a condition the same as that of the PC/ABS and is formed into a first moldable material of a strand form. The first moldable material is cut into pellets of a length 3 mm into first pellets. In this case, the flowing test is carried out in a way similar to that of the PC/ABS case. The first pellets are subjected to a injecting formation in a way similar to that of PC/ABS case to obtain a composite resin. A part of the composite resin is formed into a recycle used moldable material of a strand form as a testing piece in a way similar to that of PC/ABS case. Next, a tensile strength test is carried out with the first moldale material and the recycle used moldable material in a way similar to that of PC/ABS case. Figs. 7 and 8 are graphs showing the relation between an tensile strength and a content of the liquid crystal polymer contained in the first moldable material and recycle used moldable material, respectively. The liquid crystal polymer starts to be formed into a fiber form at a range higher than 2 to 4 % of the liquid crystal amount. It is found that the first moldable material and recycle used moldable material show the tensile strength the same as each other at the all range of the liquid crystal polymer content. Fig. 9 is a graph showing a relation between a flow length ratio and the content amount of liquid crystal polymer. It is clear from Fig. 9 that a flowing ability is greatly decreased at a liquid crystal polymer content higher than 60 %. It is difficult to achieve a reformed molding product by using the moldable material having a content of liquid crystal polymer higher than 60%. In connection with a case using PC/PBT as a thermoplastic resin, the content of liquid crystal polymer preferably ranges from 2 to 60 %. An electron microscopic observation (SEM) indicates that the liquid crystal polymer is of a powder form at the liquid crystal content of 1 %. On the other hand, the liquid crystal polymer content ranging from 2 to 5 % results in a liquid crystal polymer of a fiber form. It is understood from the observation that the liquid crystal polymer content higher than 2 makes the liquid crystal polymer to be of a fiber form and accordingly, increases the tensile strength of the resultant product. The following description will be directed to a tensile strength and a flowing ability of a reformed molding product obtained by using modified PPO as a thermoplastic resin. A liquid crystal polymer as a starting material comprises VECTRA A950 ( polyester of aromatic group, the liquid crystal transition temperature is about 280°C) made by POLYPLASTIC CO.LTD. and a thermoplastic resin PPO as a starting material comprises NORYL PX2623 made by NIPPON GE PLASTIC Co.. A composite resin is prepared by mixing the two reagents mentioned above in a given mixing ratio. Next, the composite resin is subjected to a first extrusion formation in a condition the same as that of the PC/ABS and is formed into a first molding material of a strand form. The first molding material is cut into pellets of a length 3 mm into first pellets. The first pellets are subjected to an injecting formation in a way similar to that of PC/ABS case to obtain a composite resin. A part of the composite resin is formed into a recycle used moldable material of a strand form as a testing piece in a way similar to that of PC/ABS case. Next, a tensile strength test is carried out with the first molding material and the recycle used molding material in a way similar to that of PC/ABS case. Figs. 10 and 11 are graphs showing the relation between a tensile strength and a content of the liquid crystal polymer contained in the first molding material and recycle used molding material, respectively. The liquid crystal polymer starts to be formed into a fiber form at a range higher than 3 % of the liquid crystal amount. It is found that the first moldable material and recycle used moldable material show the tensile strength the same as each other at the all range of the liquid crystal polymer content. In connection with a case using modified PPO as a thermoplastic resin, the content of liquid crystal polymer is preferably higher than 3 %. An electron microscopic observation (SEM) indicates that the liquid crystal polymer is of a powder form at the liquid crystal content of 2 %. On the other hand, the liquid crystal polymer content ranging from 3 to 5 % results in a liquid crystal polymer of a fiber form. It is understood from the observation that the liquid crystal polymer content higher than 3 makes the liquid crystal polymer to be of a fiber form and accordingly, increases the tensile strength of the resultant product. As explained above, according to the method for reforming a composite resin of the present invention, there is provided a method which comprises the steps of: crushing a used molding product of a composite resin of thermoplastic resin and liquid crystal polymer having a transition temperature of the liquid crystal resin higher than a minimum moldable temperature of the thermoplastic resin to obtain crushed particles or pieces; heating said particles or pieces at a temperature higher than the transition temperature of said liquid crystal polymer to obtain molten composite resin of thermoplastic resin and the liquid crystal polymer; extruding said molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer to obtain raw moldable material. Since the liquid crystal polymer is cut into a small size by crushing, it is caused to be combined with each other by the melting process and the combined particles or pieces of liquid crystal polymer come to be of an orientation structure and are solidified as it is. Accordingly, the raw moldable material so obtained has a tensile strength and a rigidity the same as those of the original composite resin. Further, the raw moldable material so obtained is formed into a molding product at a temperature lower than the transition temperature of the liquid crystal polymer. Hence, the molding product has the liquid crystal polymer keeping an orientation structure and has a tensile strength and a rigidity the same as those of the original composite resin. Secondarily, according to the invention there is provided a method comprising the steps of: crushing a used molding product of a composite resin of thermoplastic resin and liquid crystal polymer having a transition point of the liquid crystal resin higher than a minimum moldable temperature of the thermoplastic resin to obtain crushed particles or pieces; heating said particles or pieces at a temperature higher than the transition temperature of said liquid crystal polymer to obtain molten composite resin of thermoplastic resin and the liquid crystal polymer; and extruding said molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer to obtain a molding product in a given shape. Since the liquid crystal polymer is cut into a small size by crushing, it is caused to be combined with each other by the melting process and the combined crushed particles or pieces of liquid crystal polymer come to be of an orientation structure and are solidified as it is. Accordingly, the molding product so obtained has a tensile strength and a rigidity the same as those of the original composite resin. Thirdly, according to the present invention, the crushed particles or pieces of liquid crystal polymer are combined to each other during a formation process at a temperature higher than the transition temperature of the liquid crystal polymer, so that the liquid crystal polymer can keep a fiber structure having a length the same as that of the liquid crystal polymer contained in the original composite resin. The resultant raw moldable material or the resultant molding product has a tensile strength and rigidity the same as those of the original composite resin. Fourthly, according to the present invention, a raw moldable materials is obtained by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. Accordingly,the liquid crystal polymer in the raw moldable material is of an orientation structure aligned to the extrusion direction. This results in an improvement in the tensile strength and rigidity of the raw moldable material and the resultant molding product. Fifthly, according to the present invention, a molding product is obtained by extruding the molten composite resin at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. Accordingly, this results in an improvement in the tensile strength and rigidity of the resultant molding product. Sixthly, according to the present invention, there is obtained a raw moldable material of a strand form. Accordingly, it is easy to carry out the reformation of the raw molding material of a strand form by an injection method by cutting the raw moldable material. Seventhly, according to the present invention, there is obtained a raw moldable material of a sheet form. Accordingly, it is easy to carry out the reformation of the raw moldable material of a sheet form by a pressing formation or vacuum formation method.

Claims: Method for reforming a composite resin of liquid crystal polymer and thermoplastic resin comprising the steps of: providing a used molding product of a composite resin (10) of thermoplastic resin and liquid crystal polymer having a crystal transition temperature higher than a minimum moldable temperature of the thermoplastic resin; crushing said used molding product of a composite resin (10) into particles or pieces (14); heating said particles or pieces (14) at a temperature higher than the transition temperature of said liquid crystal polymer to obtain a molten composite resin (22); extruding said molten composite at a temperature higher than the transition temperature of said liquid crystal polymer to obtain a moldable composite material (24; 26); and forming the moldable composite material (24; 26) into a molding product (32) in a given shape at a temperature lower than the transition temperature of said liquid crystal polymer. Method according to claim 1, wherein the molten composite resin (22) is formed into a molding product (32) in a given shape at a temperatur higher than the transition temperature of the liquid crystal polymer. Method according to claim 1 or 2, wherein the liquid crystal polymer contained in the composite resin (10) used for molding product made from a thermoplastic resin and a liquid crystal polymer is of a fiber form present in the thermoplastic resin. Method according to anyone of claims 1 to 3, wherein the step of obtaining a moldable composite material (24; 26) by extruding the molten composite resin (22) at a temperature higher than the transition temperature of the liquid crystal polymer is directed to a step of obtaining a moldable composite material (24; 26) by extruding said molten composite resin (22) at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. Method according to anyone of claims 1 to 4, wherein the step of forming the molten composite resin (22) into a molding product (32) in a given shape at a temperature higher than the transition temperature of said liquid crystal polymer is directed to a step of extrusion-forming the molten composite resin (22) into a molding product (32) of a given shape at a temperature higher than the transition temperature of the liquid crystal polymer under being extended. Method according to anyone of claims 1 to 5, wherein the step of obtaining a moldable composite material (24; 26) by extruding the molten composite resin (22) at a temperature higher than the transition temperature of the liquid crystal polymer according to claim 1 or the step of obtaining a moldable composite material (24; 26) by extruding the molten composite resin (22) at a temperature higher than the transition temperature of the liquid crystal polymer under being stretched according to claim 5 is directed to a step of forming a moldable composite material of a strand form (26) or of a sheet form (24). Method according to anyone of claims 1 to 6, wherein the step of heating the crushed particles or pieces (14) comprise a mixture of used composite resins (10) having different contents of the liquid crystal resin or a mixture of a used composite resin (10) and a liquid crystal resin and/or a thermoplastic resin.

Inventors: HARA MASAO, SASAKI KEITA, SHINOMORI MASATOSHI, TOMITA TAKASHI, HARA, MASAO, SASAKI, KEITA, SHINOMORI, MASATOSHI, TOMITA, TAKASHI
Applicants: MAZDA MOTOR, MAZDA MOTOR CORPORATION
Application year: 1992
Main classification: B29B17
IPC codes: B29B13, B29C70, C08L77, B29B17, B29C47, B29C39