The invention is directed to a composite structure in which a metal member having a roughened surface and a resin member are joined in a state in which at least a portion of the roughened surface is included. The resin member is made of a molded article obtained by melt-molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin. In the roughened surface, a cumulative pore volume of a pore diameter in a range of 0.1 μm to 20 μm is in a range of 0.5 nL/mm.sup.2 or more and 5 nL/mm.sup.2 or less measured by mercury porosimetry. According to the invention, it is possible to provide a composite structure that is obtained by joining a metal member and a molded article made of polyarylene sulfide resin composition and is more excellent in joining strength, heat cycle resistance, and sealing properties, and a method for producing the composite structure.

The invention is directed to a composite structure in which a metal member having a roughened surface and a resin member are joined in a state in which at least a portion of the roughened surface is included. The resin member is made of a molded article obtained by melt-molding a polyarylene sulfide resin composition containing a polyarylene sulfide resin. In the roughened surface, a cumulative pore volume of a pore diameter in a range of 0.1 μm to 20 μm is in a range of 0.5 nL/mm.sup.2 or more and 5 nL/mm.sup.2 or less measured by mercury porosimetry. According to the invention, it is possible to provide a composite structure that is obtained by joining a metal member and a molded article made of polyarylene sulfide resin composition and is more excellent in joining strength, heat cycle resistance, and sealing properties, and a method for producing the composite structure.

A polyphenylene sulfide resin composition for automotive cooling parts contains, with respect to 100 parts by weight of a polyphenylene sulfide resin (A): 30 to 110 parts by weight of glass fibers (B); and 0.1 to 3 parts by weight of a silane compound (C) having a functional group selected from an amino group and an isocyanate group. In this polyphenylene sulfide resin composition, the PPS resin (A) has a number-average molecular weight of 7,000 to 14,000, and gives a residue amount of 0.05 to 1.0% by weight when dissolved in 20-fold amount by weight of 1-chloronaphthalene at 250° C. for 5 minutes and subsequently subjected to heat pressure filtration through a PTFE membrane filter having a pore size of 1 μm.

Provided are a purification method for a polyarylene sulfide (PAS) that can efficiently reduce the amount of a carboxyalkylamino group-containing compound in the PAS by treating the carboxyalkylamino group-containing compound in the PAS under a low pressure without using a strong acid, and a production method for a PAS having a reduced amount of the carboxyalkylamino group-containing compound in the PAS. The purification method for a PAS includes: a step of obtaining a crude PAS-containing mixture by removing a solvent from a crude reaction product containing the PAS obtained by reacting a polyhalo aromatic compound with a sulfidizing agent in an organic polar solvent; a step of bringing the crude PAS mixture into contact with water and an oxygen atom-containing solvent to convert the crude PAS into porous particles; and a step of bringing the obtained porous particles into contact with carbonated water.

Provided are a purification method for a polyarylene sulfide (PAS) that can efficiently reduce the amount of a carboxyalkylamino group-containing compound in the PAS by treating the carboxyalkylamino group-containing compound in the PAS under a low pressure without using a strong acid, and a production method for a PAS having a reduced amount of the carboxyalkylamino group-containing compound in the PAS. The purification method for a PAS includes: a step of obtaining a crude PAS-containing mixture by removing a solvent from a crude reaction product containing the PAS obtained by reacting a polyhalo aromatic compound with a sulfidizing agent in an organic polar solvent; a step of bringing the crude PAS mixture into contact with water and an oxygen atom-containing solvent to convert the crude PAS into porous particles; and a step of bringing the obtained porous particles into contact with carbonated water.

A polyphenylene sulfide resin composition for automotive cooling parts contains, with respect to 100 parts by weight of a polyphenylene sulfide resin (A): 30 to 110 parts by weight of glass fibers (B); and 0.1 to 3 parts by weight of a silane compound (C) having a functional group selected from an amino group and an isocyanate group. In this polyphenylene sulfide resin composition, the PPS resin (A) has a number-average molecular weight of 7,000 to 14,000, and gives a residue amount of 2.0 to 5.0% by weight when dissolved in 20-fold amount by weight of 1-chloronaphthalene at 250° C. for 5 minutes and subsequently subjected to heat pressure filtration through a PTFE membrane filter having a pore size of 1 μm.

Described herein are methods for making poly(aryl ether sulfone) (“PAES”) polymers and polymer compositions including the PAES polymers. The method includes reacting a first monomer and a second monomer in a reaction mixture including a base. In some embodiments, the first monomer, second monomer and base can be selected such that halogen salts are not formed during the reacting. In some embodiments, the method can also be a solvent free process. The PAES polymer and polymer compositions can be desirable in many application settings including, but not limited to, electronic components.

Described herein are methods for making poly(aryl ether sulfone) (“PAES”) polymers and polymer compositions including the PAES polymers. The method includes reacting a first monomer and a second monomer in a reaction mixture including a base. In some embodiments, the first monomer, second monomer and base can be selected such that halogen salts are not formed during the reacting. In some embodiments, the method can also be a solvent free process. The PAES polymer and polymer compositions can be desirable in many application settings including, but not limited to, electronic components.

A method for producing a polyarylene sulfide comprising: initiating a polymerization reaction by heating a mixture containing an organic polar solvent, a sulfur source, water, a polyhaloaromatic compound, and an alkali metal hydroxide in the presence of at least one auxiliary agent selected from the group consisting of carboxylates and the like, to form a reaction mixture containing a prepolymer having a conversion rate of a polyhaloaromatic compound of 50 mol % or greater, then a phase separation agent addition step of adding a phase separation agent into the reaction mixture, then continuing the polymerization reaction, and then cooling the reaction mixture, in the cooling step, the coolant being added to the reaction mixture at a temperature that is at least 5° C. higher than a maximum thickening temperature and lower than 250° C., and a cooling rate at the maximum thickening temperature being 2.2° C./min or higher and 3.9° C./min or lower.

A method for producing a polyarylene sulfide comprising: initiating a polymerization reaction by heating a mixture containing an organic polar solvent, a sulfur source, water, a polyhaloaromatic compound, and an alkali metal hydroxide in the presence of at least one auxiliary agent selected from the group consisting of carboxylates and the like, to form a reaction mixture containing a prepolymer having a conversion rate of a polyhaloaromatic compound of 50 mol % or greater, then a phase separation agent addition step of adding a phase separation agent into the reaction mixture, then continuing the polymerization reaction, and then cooling the reaction mixture, in the cooling step, the coolant being added to the reaction mixture at a temperature that is at least 5° C. higher than a maximum thickening temperature and lower than 250° C., and a cooling rate at the maximum thickening temperature being 2.2° C./min or higher and 3.9° C./min or lower.