Polyarylene sulfide resin composition for automobile headlamp component and automobile headlamp component manufactured using the same

Patent metadata

Field	Value
Publication number	US-2020263003-A1
Application number	US-202016792744-A
Country	US
Kind code	A1
Filing date	Feb 17, 2020
Priority date	Feb 18, 2019
Publication date	Aug 20, 2020
Grant date	—

Abstract

The present disclosure relates to a polyarylene sulfide resin composition for an automobile headlamp component, a method for producing the same, and an automobile headlamp component manufactured using the same. The polyarylene sulfide resin composition includes: about 45 wt % to about 75 wt % of a polyarylene sulfide resin containing about 300 ppm or less of chlorine; about 24.5 wt % to about 55 wt % of an inorganic filler; about 0.1 wt % to about 1 wt % of a nucleating agent; about 0.05 wt % to about 1 wt % of metal powder; and about 0.1 wt % to about 2.5 wt % of a composite metal hydroxide.

First claim

What is claimed is:

1 . A polyarylene sulfide resin composition for an automobile headlamp component, comprising:
about 45 wt % to about 75 wt % of a polyarylene sulfide resin having about 300 ppm or less of chlorine; about 24.5 wt % to about 55 wt % of an inorganic filler; about 0.1 wt % to about 1 wt % of a nucleating agent; about 0.05 wt % to about 1 wt % of a metal powder; and about 0.1 wt % to about 2.5 wt % of a composite metal hydroxide.

2 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin is made by comprising:
polymerizing reactants including a diiodo aromatic compound and a sulfur compound; and adding a polymerization stopping agent to the reactants at a time point where about 70 wt % or more of the diiodo aromatic compound of the reactants has reacted during the polymerizing.

3 . The polyarylene sulfide resin composition of claim 2 , wherein polymerizing is performed under initial reaction conditions of a temperature of about 180° C. to about 250° C. and a pressure of about 50 torr to about 450 torr, and then under final reaction conditions of a temperature of about 270° C. to about 350° C. and a pressure of about 0.001 torr to about 20 torr, which are obtained by performing temperature rise and pressure drop from the initial reaction conditions.

4 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin has a melting point of about 265° C. to about 290° C., a number-average molecular weight of about 5,000 to about 50,000, and a melt viscosity of about 10 poise to about 50,000 poise, as measured with a rotating disk viscometer at 300° C.

5 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin comprises about 10 ppm to about 10,000 ppm of one or more of 1) iodine present as an arylene substituent of the resin and 2) free iodine.

6 . The polyarylene sulfide resin composition of claim 1 , wherein the inorganic filler comprises fibers having an average diameter of about 6 μm to about 15 μm and an average length of about 2 mm to about 5 mm.

7 . The polyarylene sulfide resin composition of claim 1 , wherein the nucleating agent comprises one or more of borate, boron sulfide, boron chloride, boric acid, colemanite, one or more zinc borate compounds, boron carbide, boron nitride, and boron oxide.

8 . The polyarylene sulfide resin composition of claim 1 , wherein the metal powder comprises one or more of copper, nickel, titanium, palladium, chromium, gold, zinc, iron, molybdenum, cobalt, silver and platinum.

9 . The polyarylene sulfide resin composition of claim 1 , wherein the composite metal hydroxide comprises hydrotalcite.

10 . The polyarylene sulfide resin composition of claim 1 , further comprising, based on a total weight of the polyarylene sulfide resin composition, about 0.1 wt % to about 5 wt % of a compatibilizer.

11 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin composition has a metal powder and composite metal hydroxide weight ratio of about 1:1 to about 1:2.5.

12 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin composition has a heat distortion temperature (1.82 MPa, 120° C./hr) of about 260° C. or above as measured in accordance with ASTM D 648, an Izod impact strength of about 69 J/m or higher as measured for a 3.2 mm-thick specimen in accordance with ASTM D 256, and a haze of about 5% or less, as measured on a glass plate after performing a fogging test for pellets (15 g) of the polyarylene sulfide resin composition at 230° C. for 5 hours.

13 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin composition has a tensile strength of about 165 MPa or higher as measured in accordance with ASTM D 638, a flexural strength of about 230 MPa or higher as measured in accordance with ASTM D 740, and a flexural modulus of about 11,500 MPa or higher as measured in accordance with ASTM D 740.

14 . An automobile headlamp component made by comprising the polyarylene sulfide resin composition of claim 1 .

15 . The automobile headlamp component of claim 14 , wherein the automobile headlamp component comprises a base plate.

16 . An automobile headlamp comprising the polyarylene sulfide resin composition of claim 1 .

17 . An automobile headlamp comprising a base plate, in turn, comprising the polyarylene sulfide resin composition of claim 1 .

18 . The polyarylene sulfide resin composition of claim 1 , wherein the polyarylene sulfide resin composition comprises:
45 wt % to 75 wt % of a polyarylene sulfide resin having 300 ppm or less of chlorine; 24.5 wt % to 55 wt % of an inorganic filler; 0.1 wt % to 1 wt % of a nucleating agent; 0.05 wt % to 1 wt % of metal powder; and 0.1 wt % to 2.5 wt % of a composite metal hydroxide.

19 . The polyarylene sulfide resin composition of claim 1 , further comprising, based on a total weight of the polyarylene sulfide resin composition, 0.1 wt % to 5 wt % of a compatibilizer.

20 . The polyarylene sulfide resin composition of claim 1 , wherein the composite metal hydroxide has a weight ratio of 1:1 to 1:2.5.

Assignees

• Hyundai Mobis Co Ltd
• Sk Chemicals Co Ltd

Inventors

• Kim Jong Su
• Lee Seung Yeon
• Lee Jung Hwan
• Kim Ya Won
• Oh Hyeong Geun
• Shin Jong Wook
• Choi Se Ran

Classifications

• C08K7/02

  Fibres or whiskers · CPC title

• C08K5/0083

  Nucleating agents promoting the crystallisation of the polymer matrix · CPC title

• C08K3/20

  Oxides; Hydroxides {(graphene oxides C08K3/042)} · CPC title

• C08G75/0268

  using disulfides · CPC title

• C08K3/38

  Boron-containing compounds · CPC title