Polyarylene sulfide resin composition, molded article, and optical ferrule

Abstract

A polyarylene sulfide resin composition which yields a molded article with excellent toughness, as well as a molded article and an optical ferrule, which are produced using the polyarylene sulfide resin composition. In a polyarylene sulfide resin composition containing a polyarylene sulfide resin and silica particles, a specific amount of a polyarylene sulfide resin having a melt viscosity of 35 to 80 Pa.Math.s, and a specific amount of silica particles having a lower content of coarse powders with a particle size of 45 ?m or more are employed.

Claims

1. A polyarylene sulfide resin composition comprising a polyarylene sulfide resin (A) and silica particles (B), wherein: the polyarylene sulfide resin (A) has a melt viscosity, as measured at a temperature of 310? C. and a shear rate of 1200 sec.sup.?1, of 35 to 80 Pas; a content of the polyarylene sulfide resin (A) is 25 to 40% by mass based on a mass of the polyarylene sulfide resin composition; the silica particles (B) comprise smaller-particle-size silica particles (B1) and larger-particle-size silica particles (B2); a content of the smaller-particle-size silica particles (B1) is 35 to 120 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (A); a content of the larger-particle-size silica particles (B2) is 100 to 240 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (A); the smaller-particle-size silica particles (B1) have a mean particle size of 1 ?m or less; the larger-particle-size silica particles (B2) have a mean particle size of 2 ?m or more and 10 ?m or less; in sieving a sample of the silica particles (B) in a wet process using a sieve with an opening size of 45 ?m, a ratio of a mass of the silica particles (B) on the sieve to a total mass of the sample of the silica particles (B) is 10 ppm by mass or less.

2. The polyarylene sulfide resin composition according to claim 1, wherein the silica particles (B) consist of only the smaller-particle-size silica particles (B1) and the larger-particle-size silica particles (B2).

3. The polyarylene sulfide resin composition according to claim 1, wherein the content of the silica particles (B) is 150 to 300 parts by mass based on 100 parts by mass of the polyarylene sulfide resin (A).

4. The polyarylene sulfide resin composition according to claim 1, wherein a ratio of a mass of the smaller-particle-size silica particles (B1) to a sum of the mass of the smaller-particle-size silica particles (B1) and a mass of the larger-particle-size silica particles (B2) is 14 to 43% by mass.

5. A molded article comprising the polyarylene sulfide resin composition according to claim 1.

6. An optical ferrule comprising one or more optical fibers, and a resin portion enveloping the one or more optical fibers, wherein the resin portion comprises the polyarylene sulfide resin composition according to claim 1.

Description

EXAMPLES

(1) The present embodiments will now be specifically described with reference to Examples and Comparative Examples, but the present embodiments are not limited to these Examples.

Examples 1 to 9, and Comparative Examples 1 to 3

(2) In Examples and Comparative Examples, the following materials were used as materials for PAS resin compositions.

Component (A): PAS Resin

(3) A1: PPS resin, FORTRON KPS (manufactured by Kureha Corporation, melt viscosity: 20 Pas (shear rate: 1200 sec.sup.?1 at 310? C.))

(4) A2: PPS resin, FORTRON KPS (manufactured by Kureha Corporation, melt viscosity: 30 Pas (shear rate: 1200 sec.sup.?1 at 310? C.))

(5) A3: PPS resin, FORTRON KPS (manufactured by Kureha Corporation, melt viscosity: 130 Pas (shear rate: 1200 sec.sup.?1 at 310? C.)

Measurement of Melt Viscosity of PPS Resin

(6) The melt viscosity at a barrel temperature of 310? C. and a shear rate of 1200 sec.sup.?1 was measured using Capilograph manufactured by Toyo Seiki Seisaku-sho, Ltd. A flat die of 1 mm??20 mmL was used as a capillary. The results are shown in Table 1.

Component: Silica Particles (B)

(7) Smaller-particle-size silica B1 (mean particle size: 0.5 ?m, percentage content of coarse powder having a particle size of more than 45 ?m: 0 ppm by mass, manufactured by Admatechs Co., Ltd., ADMAFINE SC2500-SQ)

(8) Smaller-particle-size silica B1 (mean particle size: 0.5 ?m, percentage content of coarse powder having a particle size of more than 45 ?m: 100 ppm by mass, manufactured by Admatechs Co., Ltd., ADMAFINE SOC2)

(9) Larger-particle-size silica B2 (mean particle size: 4.2 ?m, percentage content of coarse powder having a particle size of more than 45 ?m: 0 ppm by mass, manufactured by Denka Co., Ltd., FB-5SDC)

Other Components

(10) Silane coupling agent (alkoxysilane compound: manufactured by Shin-Etsu Chemical Co., Ltd., KBE-903P)

(11) Pellets of PAS resin compositions of Examples and Comparative Examples were each prepared by melt kneading the respective components in amounts specified in Table 1 in a twin screw extruder with a cylinder temperature of 320? C.

(12) The resultant pellets of Examples and Comparative Examples were used to measure their tensile strain at break and melt viscosity according to the methods described below. The results of these measurements are shown in Table 1. It is noted that a melt viscosity of 600 Pas or less was determined as O, and a melt viscosity of more than 600 Pas was determined as X.

Measurement of Tensile Strain at Break

(13) The pellets described above were used to prepare test pieces according to ISO 3167 (width: 10 mm; and thickness: 4 mmt) by injection molding with a cylinder temperature of 320? C. and a die temperature of 150? C. These test pieces were used to measure the tensile strain at break (%) according to ISO 527-1,2. The cases where a value of the tensile strain at break was 0.8% or more were determined as 0, and the cases where a value of the tensile strain at break was less than were determined as X.

Fluidity: Melt Viscosity (Pas)

(14) The melt viscosity at a barrel temperature of 310? C. and a shear rate of 1000 sec.sup.?1 was measured using Capilograph manufactured by Toyo Seiki Seisaku-sho, Ltd. A flat die of 1 mm??20 mmL was used as a capillary.

(15) TABLE-US-00001 TABLE 1 Example Comparative Example 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 Component A1 93 93 (A) A2 77 77 77 77 77 62 40 77 77 93 77 62 40 16 93 (Parts by A3 23 23 23 23 23 38 60 23 23 7 7 23 38 60 84 7 7 mass) Polymer melt 40 40 40 40 40 50 70 40 40 20 30 40 50 70 100 20 30 viscosity (Pa .Math. s) Component B1 35 39 52 54 70 70 70 97 120 70 70 (B) B1 70 70 70 70 70 70 (Pars by B2 211 117 104 240 176 176 176 129 174 176 176 176 176 176 176 176 176 mass) Total content of 246 156 156 294 246 246 246 227 294 246 246 246 246 246 246 246 246 component (B) (Parts by mass) Ratio of mass of 14.3 25.0 33.3 18.3 28.6 28.6 28.6 42.9 40.9 28.6 28.6 28.6 28.6 28.6 28.6 28.6 28.6 smaller-particle-size silica particles (% by mass) Silane coupling agent 1.4 1.0 1.0 1.6 1.4 1.4 1.4 1.3 1.6 1.4 1.4 1.4 1.4 1.4 1.4 1.4 1.4 (parts by mass) Tensile % 0.9 1.0 1.0 0.9 0.9 1.0 1.1 0.9 0.9 0.6 0.6 0.7 0.7 0.8 0.9 0.7 0.7 strain at Deter- ? ? ? ? ? ? ? ? ? X X X X X X X X break mination Melt (Pa .Math. s) 460 360 350 500 450 500 540 430 470 280 400 440 490 550 650 310 420 viscosity Deter- ? ? ? ? ? ? ? ? ? ? ? ? ? ? X X X mination

(16) It can be seen from Examples 1 to 9 that the polyarylene sulfide resin compositions which contain the PAS resin (A) having a melt viscosity of 35 to 80 Pa.Math.s, the smaller-particle-size silica particles (B1) having a mean particle size of 1 ?m or less, and the larger-particle-size silica particles (B2) having a mean particle size of 2 ?m or more and 10 ?m or less in the respective predetermined amounts, in which the ratio of the mass of coarse silica particles having a particle size of 45 ?m or more to the mass of the silica particles (B) is 10 ppm by mass or less, have both excellent tensile strain at break and excellent fluidity. Therefore, it can be seen that the PAS resin composition according to the present embodiment is suitable for PAS resin compositions for use in molding of optical ferrules.