WO2023013650A1 - アンテナ部材 - Google Patents
アンテナ部材 Download PDFInfo
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- WO2023013650A1 WO2023013650A1 PCT/JP2022/029690 JP2022029690W WO2023013650A1 WO 2023013650 A1 WO2023013650 A1 WO 2023013650A1 JP 2022029690 W JP2022029690 W JP 2022029690W WO 2023013650 A1 WO2023013650 A1 WO 2023013650A1
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- temperature
- resin composition
- thermoplastic resin
- antenna member
- acid
- Prior art date
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
- C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
- C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
- C08L71/12—Polyphenylene oxides
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/36—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith
- H01Q1/38—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith formed by a conductive layer on an insulating support
Definitions
- the present invention relates to an antenna member.
- filters are made of metal or ceramic, and many surfaces must be coated with metal to filter radio waves.
- a resin that can be coated by plating or sputtering is required.
- the antenna element (pendulum) of communication equipment can exhibit its performance as an antenna by drawing a metal circuit on a resin with a low dielectric loss tangent.
- a surface-mounted dielectric antenna used in mobile communication devices such as mobile phones and wireless LANs, those composed of dielectric ceramics alone, resins alone, and ceramic-containing resin compositions have been proposed.
- a surface-mounted dielectric antenna in which the antenna substrate is made of a single ceramic or a single resin, or a styrene-based resin having a syndiotactic structure with good plating properties and a relative permittivity real part of about 18. and a method for producing the same (see Patent Document 2).
- Patent Document 3 a resin composition in which spherical dielectric ceramic powder is mixed with a resin material at a ratio of 40 vol% to 70 vol% (volume%) in the composition, and the aspect ratio is increased to enable high filling.
- a metal titanate fiber adjusted to 3 to 5 and a composite material in which this is combined with a thermoplastic resin or the like is disclosed (see Patent Document 4).
- a resin composition When a resin composition is used for the above antenna member, it is required to have excellent mechanical properties, electrical properties, and heat resistance, as well as excellent dimensional stability. In addition, from the viewpoint of easily molding into a desired shape, molding by injection molding is required. Furthermore, a material that can be coated with a metal by plating or sputtering and whose metal coating does not peel off at high temperatures is required. Specifically, since any component generates heat during communication, it is required that the resin itself has heat resistance, that there is little dimensional change even in a high-temperature region, and that the metal coating does not peel off. Since the antenna is exposed to the external environment and includes heat-generating components inside, the temperature inside may become high.
- the antenna filter is made of metal or ceramic and occupies a considerable weight in the base station.
- the present invention provides an antenna that is molded by injection molding and adaptable to all environments such as low temperature, high temperature, and humidity, with little dimensional change and dielectric loss tangent change in high temperature regions while maintaining adhesion to the metal film.
- the purpose is to provide parts.
- the present inventors have found that by using a specific resin composition for the antenna member, the weight of the communication device can be reduced and the assembly work process can be simplified while maintaining the antenna performance in any environment. The inventors have found that it can contribute to simplification and arrived at the present invention.
- thermoplastic resin composition contains (Aa) a polyphenylene ether-based resin,
- the thermoplastic resin composition has a deflection temperature under load (DTUL) of 120° C. or higher,
- DTUL deflection temperature under load
- the temperature of the thermoplastic resin composition when the temperature is raised from -30 ° C. to 120 ° C. is divided into temperature ranges of 10 ° C., and the low temperature side of the two adjacent temperature ranges is the low temperature range and the high temperature.
- the high-temperature expansion coefficient (mm / mm / ° C.) in the TD direction of the resin composition measured by the method described in ISO 11359 in the region has the following relationship in any of the two adjacent temperature regions
- the antenna member according to [1] wherein the temperature dependence of the dielectric loss tangent at 28 GHz of the thermoplastic resin composition satisfies the following conditions.
- the difference between the dielectric loss tangent at 23° C. and the dielectric loss tangent at 120° C. is 0.004 or less.2.
- the difference between the dielectric loss tangent at 23°C and the dielectric loss tangent at 140°C is 0.004 or less [3]
- the temperature of the thermoplastic resin composition when the temperature is raised from ⁇ 30° C. to 120° C. is divided into temperature ranges of 10° C., and the resin composition is measured by the method described in ISO 11359 for each temperature range.
- the temperature of the thermoplastic resin composition when the temperature is raised from ⁇ 30° C. to 120° C. is divided into temperature ranges of 10° C., and the resin composition is measured by the method described in ISO 11359 for each temperature range.
- the antenna member according to [3], wherein the maximum expansion coefficient in the TD direction of the object is 10 ⁇ 10 ⁇ 5 mm/mm/° C. or less.
- thermoplastic resin composition contains (B) 10% by mass or more of an inorganic filler.
- thermoplastic resin composition contains (Aa) a polyphenylene ether-based resin in an amount of 10% by mass or more.
- metal coating is formed by chromic acid etching and electroless copper plating.
- the thermoplastic resin composition comprises (Acb) at least one block mainly composed of aromatic vinyl monomer units and at least one block mainly composed of conjugated diene monomer units, The antenna member according to any one of [1] to [11], comprising a block copolymer and/or a hydrogenated product of the block copolymer.
- the present invention there is little dimensional change and dielectric loss tangent change in a high temperature region while maintaining adhesion to the metal film, it is molded by injection molding, and it can be applied to all environments such as low temperature, high temperature, and humidity. An antenna member can be obtained.
- FIG. 4 is a diagram for explaining a method of cutting out a test piece from an ISO dumbbell for evaluation in order to measure the expansion coefficient in Examples.
- the antenna member of the present embodiment has an injection molded body made of a thermoplastic resin composition, and is used by coating at least a part of the injection molded body with a metal, and the thermoplastic resin composition comprises (Aa ) containing a polyphenylene ether-based resin, the deflection temperature under load (DTUL) of the thermoplastic resin composition is 120 ° C. or higher, and the temperature of the thermoplastic resin composition is increased from -30 ° C. to 120 ° C. is divided into temperature ranges of 10 ° C., and the low temperature side of the two adjacent temperature ranges is the low temperature range, and the high temperature side is the high temperature range.
- the thermoplastic resin composition comprises (Aa ) containing a polyphenylene ether-based resin, the deflection temperature under load (DTUL) of the thermoplastic resin composition is 120 ° C. or higher, and the temperature of the thermoplastic resin composition is increased from -30 ° C. to 120 ° C. is divided into temperature ranges of 10 ° C., and the low
- the low temperature expansion coefficient (mm / mm / ° C.) in the TD direction of the resin composition, and the high temperature in the TD direction of the resin composition, measured by the method described in ISO 11359 in the high temperature region The temperature range expansion coefficient (mm/mm/°C) satisfies the following relationship in any of the two adjacent temperature ranges. -50 ⁇ ((high temperature expansion coefficient - low temperature expansion coefficient) / low temperature expansion coefficient) ⁇ 100 ⁇ 50
- thermoplastic resin composition in this embodiment will be described in detail below.
- thermoplastic resin in the present embodiment refers to a resin component excluding fillers, inorganic fillers, and the like.
- resin components include various resins used for molding, such as polyphenylene ether-based resins, polyester-based resins, polyamide-based resins, polycarbonate-based resins, vinyl-based resins, olefin-based resins, acrylic-based resins, and aromatic resins. family-based resins and the like.
- thermoplastic resin of the present embodiment can improve the adhesion to the metal film and the temperature dependence of the dielectric loss tangent.
- the (A) thermoplastic resin of the present embodiment can also contain a resin component mainly for improving impact resistance, such as an olefinic thermoplastic elastomer or a hydrogenated block copolymer.
- thermoplastic resin of the present embodiment may contain (Ab) crystalline resin and other thermoplastic resins at the same time, polyester resin, polyamide resin, polycarbonate resin, vinyl resin, Olefin-based resins, acrylic-based resins, aromatic-based resins, and the like are included.
- Olefin-based resins are preferably used from the viewpoint of low dielectric loss tangent, and more preferably resins having sufficient heat resistance, such as polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and the like.
- polyester resin cyclic olefin polymer (COP), cycloolefin copolymer, polyolefin polymer such as methylpentene polymer (TPX), and the like.
- olefin-based thermoplastic elastomers examples include polyolefin homopolymers such as polyethylene and polypropylene; polyolefin copolymers such as ethylene-propylene copolymers, ethylene-butylene copolymers and ethylene-octene copolymers.
- polyethylene homopolymers include high-pressure low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), and the like.
- Examples of the hydrogenated block copolymer include a hydrogenated block copolymer obtained by hydrogenating a block copolymer composed of a polystyrene block and a conjugated diene compound polymer block.
- the structure of the block copolymer before hydrogenation is not particularly limited, and for example, when a polystyrene block chain is represented by S and a conjugated diene compound polymer block chain is represented by B, SBS and SBSB , (SB-) 4 -S, and SBSBS.
- (Aa) polyphenylene ether resin Specific examples of the (Aa) polyphenylene ether resin (hereinafter sometimes simply referred to as "(Aa) component") in the present embodiment include, for example, poly(2,6-dimethyl-1 ,4-phenylene ether), poly(2-methyl-6-ethyl-1,4-phenylene ether), poly(2-methyl-6-phenyl-1,4-phenylene ether), poly(2,6-dichloro -1,4-phenylene ether) and the like, and copolymers of 2,6-dimethylphenol and other phenols (for example, 2,3-phenylene ethers such as those described in JP-B-52-17880). , 6-trimethylphenol and 2-methyl-6-butylphenol).
- particularly preferred polyphenylene ethers include poly(2,6-dimethyl-1,4-phenylene ether), copolymers of 2,6-dimethylphenol and 2,3,6-trimethylphenol, or A mixture.
- Examples of the component (Aa) include homopolymers having a repeating unit structure represented by the following formula (1), and copolymers having a repeating unit structure represented by the following formula (1). .
- the above component (Aa) may be used alone or in combination of two or more.
- R 1 , R 2 , R 3 , and R 4 each independently represent a hydrogen atom, a halogen atom, a primary alkyl group having 1 to 7 carbon atoms, or a selected from the group consisting of secondary alkyl groups, phenyl groups, haloalkyl groups, aminoalkyl groups, hydrocarbonoxy groups, and halohydrocarbonoxy groups in which at least two carbon atoms separate the halogen and oxygen atoms; is a monovalent group that
- the method for producing the polyphenylene ether-based resin is not particularly limited as long as it can be obtained by a known method. , produced by oxidative polymerization of 2,6-xylenol, the method described in US Pat. No. 3,306,874, US Pat. Examples include the production methods described in JP-A-50-51197, JP-B-52-17880 and JP-B-63-152628.
- the preferred range of reduced viscosity (0.5 g / dL chloroform solution, 30 ° C., measured with an Ubbelohde viscosity tube) of (Aa) polyphenylene ether resin in the present embodiment is 0.30 to 0.80 dL / g, and more Preferably between 0.35 and 0.75 dL/g, most preferably between 0.38 and 0.55 dL/g.
- Aa It is preferable that the reduced viscosity of the polyphenylene ether-based resin is within this range because of excellent properties such as impact resistance and heat resistance.
- stabilizers can be suitably used to stabilize the (Aa) polyphenylene ether resin.
- stabilizers include metallic stabilizers such as zinc oxide and zinc sulfide, and organic stabilizers such as hindered phenol stabilizers, phosphorus stabilizers, and hindered amine stabilizers.
- (Aa) is less than 5 parts by mass with respect to 100 parts by mass of the polyphenylene ether resin.
- additives that can be added to the (Aa) polyphenylene ether resin are also added in an amount of less than 10 parts by mass with respect to 100 parts by mass of the (Aa) polyphenylene ether resin. I do not care.
- the component (Aa) is obtained by reacting the homopolymer and/or the copolymer with a styrene-based monomer or a derivative thereof and/or an ⁇ , ⁇ -unsaturated carboxylic acid or a derivative thereof. It may be a modified polyphenylene ether obtained by Here, the amount of grafting or addition of the styrene-based monomer or derivative thereof and/or ⁇ , ⁇ -unsaturated carboxylic acid or derivative thereof is 0.01 to 0.01 with respect to 100% by mass of component (Aa). It is preferably 10% by mass.
- Examples of the method for producing the modified polyphenylene ether include a method of reacting at a temperature of 80 to 350° C. in the presence or absence of a radical generator in a molten state, a solution state, or a slurry state.
- polyphenylene ether a mixture of the homopolymer and/or copolymer and the modified PPE in any ratio may be used.
- the (Aa) The content of the polyphenylene ether resin is preferably 50% by mass or more, preferably 55% by mass or more, and more preferably 60% by mass or more. Moreover, it is preferable that it is 85 mass % or less from a moldability viewpoint.
- thermoplastic resin 100% by mass
- the content of (Aa) polyphenylene ether resin is preferably 5% by mass or more, preferably 10% by mass or more, and more preferably 15% by mass or more. Moreover, it is preferable that it is 90 mass % or less from a fluid viewpoint.
- the polyphenylene ether resin is preferably 5 parts by mass or more, more preferably 10 parts by mass or more, and still more preferably 15 parts by mass or more. Moreover, it is preferable that it is 90 mass parts or less from a fluid viewpoint.
- This embodiment may contain (Ab) a crystalline resin.
- (Aba) polyamide, (Abb) polypropylene, and (Abc) polyphenylene sulfide resin can be preferably used.
- crystalline resins such as polyethylene, polyacetal, polyethylene terephthalate, polybutylene terephthalate, polyetheretherketone, liquid crystal polymer, and polytetrafluoroethylene can be used.
- each of the (Ab) crystalline resins is 90% by mass or less, more preferably 80% by mass or less, when the entire thermoplastic resin composition is taken as 100% by mass. Yes, more preferably 85% by mass or less.
- Polyamides are generally obtained by ring-opening polymerization of lactams, polycondensation of diamines and dicarboxylic acids, polycondensation of ⁇ -aminocarboxylic acids, etc., but are not limited to resins obtained by these methods.
- lactams include ⁇ -caprolactam, enantholactam, and ⁇ -laurolactam.
- diamines are roughly classified into aliphatic, alicyclic and aromatic diamines.
- Specific examples of diamines include tetramethylenediamine, hexamethylenediamine, undecamethylenediamine, dodecamethylenediamine, tridecamethylenediamine, 2,2,4-trimethylhexamethylenediamine, and 2,4,4-trimethylhexamethylenediamine.
- Dicarboxylic acids are roughly classified into aliphatic, alicyclic and aromatic dicarboxylic acids. Specific examples of dicarboxylic acids include adipic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, 1,1,3-tridecanedioic acid, 1,3-cyclohexanedicarboxylic acid, terephthalic acid, isophthalic acid, and naphthalene dicarboxylic acid. acid, dimer acid and the like.
- aminocarboxylic acids specifically, ⁇ -aminocaproic acid, 7-aminoheptanoic acid, 8-aminooctanoic acid, 9-aminonananoic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, 13-aminotridecane acids and the like.
- any of these lactams, diamines, dicarboxylic acids, and ⁇ -aminocarboxylic acids can be used alone or as a mixture of two or more kinds of copolymerized polyamides obtained by polycondensation.
- polyamides obtained by copolymerizing multiple polyamides with an extruder or the like can also be used.
- the preferred polyamides are the aliphatic polyamides polyamide 6, polyamide 6,6, polyamide 4,6, polyamide 11, polyamide 12; and the semi-aromatic polyamides polyamide 9,T, polyamide 6/6,T, polyamide 6,6 /6,T, polyamide 6,6/6,I, polyamide MXD,6, more preferably polyamide 6,6, polyamide 6, polyamide 9,T, polyamide 6,6/6 , I is one or more polyamides.
- the (Aba) polyamide according to the present embodiment includes a dicarboxylic acid unit (a) containing 60 to 100 mol% of a terephthalic acid unit and 60 to 100 mol of an aliphatic diamine unit having 9 to 12 carbon atoms. % containing diamine units (b). is preferable from the viewpoint of water absorption and heat resistance.
- the dicarboxylic acid unit (a) in the present embodiment contains 60 to 100 mol%, preferably 70 to 100 mol%, more preferably 80 to 100 mol% of the terephthalic acid unit in the unit (a). and more preferably 90 to 100 mol %, still more preferably 100 mol %.
- the said molar ratio exists in this range, it will become the resin composition excellent in heat resistance. It also tends to be excellent in high-cycle moldability when molding complex-shaped or large-sized molded products.
- the dicarboxylic acid unit (a) may contain dicarboxylic acid units other than terephthalic acid units.
- dicarboxylic acid units include, but are not limited to, malonic acid, dimethylmalonic acid, succinic acid, glutaric acid, adipic acid, 2-methyladipic acid, trimethyladipic acid, pimelic acid, 2,2-dimethylglutarate.
- aromatic dicarboxylic acids such as diphenic acid, 4,4'-oxydibenzoic acid, diphenylmethane-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, and 4,4'-biphenyldicarboxylic acid units
- aromatic dicarboxylic acids such as diphenic acid, 4,4'-oxydibenzoic acid, diphenylmethane-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, and 4,4'-biphenyldicarboxylic acid units
- the dicarboxylic acid unit other than the above terephthalic acid unit may be contained in the dicarboxylic acid unit (a) in an amount of 40 mol% or less, more preferably 30 mol% or less, still more preferably 20 mol% or less, Still more preferably 10 mol % or less, most preferably 0 mol %.
- the diamine unit (b) in the present embodiment contains 60 to 100 mol%, preferably 70 to 100 mol%, more preferably 80 to 100 mol% of an aliphatic diamine unit having 9 to 12 carbon atoms. and more preferably 90 to 100 mol %, still more preferably 100 mol %.
- the resin composition has an excellent balance between low water absorption and heat resistance.
- the diamine unit (b) may be linear or branched.
- Linear aliphatic diamines constituting the diamine unit (b) are not limited to the following, but examples include 1,9-nonanediamine (also referred to as nonamethylenediamine), decamethylenediamine, undeca methylenediamine, dodecamethylenediamine.
- the aliphatic diamine constituting the aliphatic diamine unit having a substituent branched from the main chain, which constitutes the diamine unit (b), is not limited to the following, for example, 2,2,4- trimethylhexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, 2-methyl-1,8-octanediamine (also called 2-methyloctamethylenediamine), and 2,4-dimethyloctamethylenediamine. .
- the diamine unit (b) preferably contains a 1,9-nonanediamine unit and/or a 2-methyl-1,8-octanediamine unit from the viewpoint of the balance of mechanical strength, low water absorption, and heat resistance. Among them, 1,9-nonanediamine units and 2-methyl-1,8-octanediamine units are preferably used in combination.
- the molar ratio to the units (1,9-nonanediamine units/2-methyl-1,8-octanediamine units) is preferably in the range of 100/0 to 20/80.
- the molar ratio is more preferably 95/5 to 60/40, even more preferably 90/10 to 75/25. When the molar ratio is within this range, the resin composition tends to be particularly excellent in heat resistance.
- the diamine unit (b) may contain diamine units other than aliphatic diamine units having 9 to 12 carbon atoms.
- diamine units include, but are not limited to, ethylenediamine, propylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, heptamethylenediamine, octamethylenediamine, and 2-methylpentamethylenediamine (2-methyl -1,5-diaminopentane); cycloaliphatic diamines such as 1,4-cyclohexanediamine, 1,3-cyclohexanediamine, and 1,3-cyclopentanediamine; Examples include units derived from aromatic diamines such as diamine.
- the diamine unit other than the aliphatic diamine unit having 9 to 12 carbon atoms may be contained in the dicarboxylic acid unit (ba) in the range of 40 mol% or less, more preferably 30 mol% or less, and further It is preferably 20 mol % or less, still more preferably 10 mol % or less, and most preferably 0 mol %.
- Preferable examples of the (Aba) polyamide of the present embodiment include polyamide 9, T, 10, T and the like.
- the (Aba) polyamide of the present embodiment is a lactam unit such as butyrolactam, pivalolactam, ⁇ -caprolactam, caprylollactam, enantholactam, and undecanolactam within a range that does not impair the purpose of the present embodiment.
- 6-aminocaproic acid, 11-aminoundecanoic acid, and aminocarboxylic acid units such as 12-aminododecanoic acid, trivalent or higher polyvalent amine units such as bishexamethylenetriamine, and trimellitic acid, trimesic acid, and A trivalent or higher polyvalent carboxylic acid unit such as pyromellitic acid may also be included.
- the total proportion (mol%) of these units in the (Aba) polyamide is preferably 20 mol% or less, more preferably 10 mol% or less, with respect to the entire polyamide. It is more preferably mol % or less.
- the content of the component (Aba) is preferably 25 to 75% by mass when the (A) thermoplastic resin is 100% by mass, More preferably 30 to 75% by mass, still more preferably 30 to 70% by mass.
- the content of component (Aba) is within this range, a resin excellent in mechanical strength, low water absorption, dimensional accuracy and weld strength can be obtained.
- thermoplastic resin composition of the present embodiment when the total of the component (Aa) and the component (Aba) is 100 parts by mass, the content of the component (Aba) is 50 to 95 parts by mass, preferably 60 to 95 parts by mass, more preferably 60 to 90 parts by mass. When the content of the component (Aba) is within this range, the thermoplastic resin composition is excellent in mechanical strength, low water absorption, dimensional accuracy, and weld strength, and high cycle molding becomes possible. .
- the method for producing the (Aba) polyamide is not particularly limited, and examples thereof include the following various methods. 1) Aqueous solutions or suspensions in water of dicarboxylic acids and diamines, or mixtures of dicarboxylic acids and diamine salts with other components such as lactams and/or aminocarboxylic acids (these are hereinafter abbreviated as "mixtures thereof") A method of heating an aqueous solution or water suspension of (hereinafter also referred to as “thermal melt polymerization method”) and polymerizing while maintaining the molten state.); 2) A method of heating an aqueous solution or water suspension of a dicarboxylic acid and a diamine or a mixture thereof and taking out the precipitated prepolymer (“prepolymer method”); 3) A method of increasing the degree of polymerization of a polyamide obtained by a hot melt polymerization method while maintaining a solid state at a temperature below the melting point (“hot melt polymerization/solid phase polymer
- the polymerization form in the method for producing polyamide is not limited to the following, and examples thereof include batch type and continuous type.
- the polymerization apparatus is not particularly limited, and known apparatuses (for example, an autoclave reactor, a tumbler reactor, an extruder reactor such as a kneader, etc.) can also be used.
- known apparatuses for example, an autoclave reactor, a tumbler reactor, an extruder reactor such as a kneader, etc.
- the (Aba) terminal group of the polyamide contained in the thermoplastic resin composition of the present embodiment participates in the reaction with the (Aa) polyphenylene ether resin.
- Polyamide-based resins usually have an amino group or a carboxyl group as terminal groups. In general, the higher the terminal carboxyl group concentration, the lower the impact resistance and the higher the fluidity. In general, when the terminal amino group concentration increases, the impact resistance tends to improve and the fluidity tends to decrease.
- the physical properties of the thermoplastic resin composition of the present embodiment are not limited to these tendencies.
- the terminal amino group concentration of component (Aba) is preferably 1 to 80 ⁇ mol/g, more preferably 5 to 60 ⁇ mol/g, and even more preferably less than 10 to 45 ⁇ mol/g. , 20 to 40 ⁇ mol/g.
- the terminal carboxyl group concentration of component (Aba) is preferably 20 to 150 ⁇ mol/g, more preferably 30 to 130 ⁇ mol/g.
- the concentration of each terminal group of these polyamides can be adjusted using a known method. For example, a method of adding one or more selected from a diamine compound, a monoamine compound, a dicarboxylic acid compound, a monocarboxylic acid compound and the like so as to obtain a predetermined terminal group concentration during polymerization of the polyamide.
- Terminal amino group concentration and terminal carboxyl group concentration can be measured by various methods. For example, from the viewpoint of accuracy and simplicity, a method of determining from the integrated value of characteristic signals corresponding to each terminal group by 1 H-NMR is preferred. For example, as a specific example of the method for quantifying the terminal group concentration of a polyamide-based resin, the method described in Examples of JP-A-07-228689 can be mentioned. Specifically, the number of each terminal group is determined by 1 H-NMR (500 MHz, measured at 50°C in deuterated trifluoroacetic acid), and the accuracy is determined from the integrated value of the characteristic signal corresponding to each terminal group. , is preferred for simplicity.
- 1 H-NMR 500 MHz, measured at 50°C in deuterated trifluoroacetic acid
- the intrinsic viscosity [ ⁇ ] of the polyamide is measured, and the total number of molecular chain end groups can be calculated using the relationship of the following formula.
- Mn 21900 [ ⁇ ] - 7900 (Mn represents number average molecular weight)
- Total number of molecular chain end groups (eq/g) 2/Mn
- terminal blocking agent 10 to 95% of the terminal groups of the molecular chains are preferably blocked with a terminal blocking agent.
- the lower limit of the rate at which the terminal groups of the molecular chains of the polyamide are blocked is more preferably 40% or more, and even more preferably 60% or more.
- the upper limit of the terminal capping ratio is preferably 95% or less, more preferably 90% or less.
- the terminal capping rate of the polyamide can be determined according to the following formula (1) by measuring the number of terminal carboxyl groups, terminal amino groups, and terminal groups blocked by the terminal blocking agent present in the polyamide. .
- the terminal blocking agent is not particularly limited as long as it is a monofunctional compound having reactivity with the amino group or carboxyl group at the end of the polyamide. Acids and monoamines are preferred, and monocarboxylic acids are more preferred from the viewpoint of ease of handling. In addition, acid anhydrides, monoisocyanates, monoacid halides, monoesters, monoalcohols, and the like can be used as terminal blockers.
- the monocarboxylic acid used as a terminal blocking agent is not particularly limited as long as it is reactive with an amino group. Examples include acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, caprylic acid, and laurin.
- acids tridecanoic acid, myristic acid, palmitic acid, stearic acid, pivalic acid, isobutyric acid and other aliphatic monocarboxylic acids; cyclohexanecarboxylic acid and other alicyclic monocarboxylic acids; benzoic acid, toluic acid, ⁇ -naphthalenecarboxylic acid , ⁇ -naphthalenecarboxylic acid, methylnaphthalenecarboxylic acid, aromatic monocarboxylic acids such as phenylacetic acid; and any mixture thereof.
- acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, caprylic acid, lauric acid, tridecanoic acid, myristic acid, palmitic acid, Stearic acid and benzoic acid are preferred, and acetic acid and benzoic acid are more preferred.
- the monoamine used as the terminal blocker is not particularly limited as long as it has reactivity with carboxyl groups. Examples include methylamine, ethylamine, propylamine, butylamine, hexylamine, octylamine, decylamine, and stearyl. Aliphatic monoamines such as amine, dimethylamine, diethylamine, dipropylamine and dibutylamine; Alicyclic monoamines such as cyclohexylamine and dicyclohexylamine; Aromatic monoamines such as aniline, toluidine, diphenylamine and naphthylamine; is mentioned.
- butylamine, hexylamine, octylamine, decylamine, stearylamine, cyclohexylamine, and aniline are preferred from the viewpoint of reactivity, boiling point, stability of capped ends, and economy, and butylamine, hexylamine, and octyl Amines are more preferred.
- transition metals and halogens may be present not only in the polyamide but also in the resin composition.
- the type of transition metal is not particularly limited, and includes, for example, iron, copper, cerium, nickel, cobalt, etc. Among these, copper is preferable from the viewpoint of long-term thermal stability.
- the type of halogen is not particularly limited, bromine and iodine are preferable from the viewpoint of corrosion prevention of production equipment and the like.
- the content of the transition metal is preferably 1 ppm or more and less than 200 ppm on a mass basis when the total of the component (Aa) and the component (Aba) in this embodiment is 100 parts by mass, It is more preferably 5 ppm or more and less than 100 ppm.
- the halogen content is preferably 500 ppm or more and less than 1500 ppm on a mass basis when the total of the component (Aa) and the component (Aba) in this embodiment is 100 parts by mass. , 700 ppm or more and less than 1200 ppm.
- the method of adding these transition metals and halogens to the resin composition is not particularly limited.
- Preferred among these methods are a method of adding during polymerization of polyamide, and a method of adding after producing master pellets in which transition metal and/or halogen are added to polyamide at a high concentration.
- organic stabilizers in addition to the transition metals and/or halogens described above, known organic stabilizers can be used without any problem.
- organic stabilizers examples include hindered phenolic antioxidants such as Irganox 1098 (manufactured by Ciba Specialty Chemicals Co., Ltd.) and Irgafos 168 (manufactured by Ciba Specialty Chemicals Co., Ltd.). lactone-based heat stabilizers represented by HP-136 (manufactured by Ciba Specialty Chemicals Co., Ltd.), sulfur-based heat-resistant stabilizers, hindered amine-based light stabilizers, and the like.
- a hindered phenol-based antioxidant, a phosphorus-based processing heat stabilizer, or a combination thereof is more preferable.
- a preferred blending amount of these organic stabilizers is 0.001 to 1 part by mass with respect to 100 parts by mass of (Aba) polyamide.
- the (Abb) polypropylene-based resin is not particularly limited, and examples thereof include homopolymers and/or copolymers having a repeating unit structure of propylene, such as crystalline propylene homopolymers, Preferred are crystalline propylene-ethylene block copolymers and mixtures of crystalline propylene homopolymers and crystalline propylene-ethylene block copolymers.
- the crystalline propylene-ethylene block copolymer is not particularly limited, and examples thereof include those having a crystalline propylene homopolymer portion and a propylene-ethylene random copolymer portion.
- the melt mass flow rate (hereinafter also referred to as “MFR”) of the component (Abb) suppresses the drawdown during combustion of the resin composition, and improves the balance between fluidity and mechanical strength. , preferably 0.1 g/10 min or more, more preferably 0.3 g/10 min or more, particularly preferably 0.5 g/10 min or more, and 15 g/10 min or less. It is preferably 6 g/10 minutes or less, and particularly preferably 3 g/10 minutes or less.
- the MFR can be measured under conditions of a temperature of 230° C. and a load of 2.16 kg in accordance with ISO1133. Specifically, the MFR can be measured by the method described in Examples below.
- the method for producing the component (Abb) is not particularly limited, and known methods can be used.
- a specific example of the method for producing polypropylene for example, in the presence of a polymerization catalyst composition containing a titanium trichloride catalyst or a titanium halide catalyst or the like supported on a carrier such as magnesium chloride, and an alkylaluminum compound, a temperature of 0 to A method of polymerizing propylene under conditions of 100° C. and a pressure of 3 to 100 atmospheres can be mentioned.
- a chain transfer agent such as hydrogen may be added in order to adjust the molecular weight of the polymer.
- an electron-donating compound is added to the polymerization system as an internal donor component or an external donor component in order to increase the isotacticity of the obtained polypropylene and the polymerization activity of the polymerization system, can be further included.
- electron-donating compounds are not particularly limited, and known compounds can be used.
- electron-donating compounds include ester compounds such as ⁇ -caprolactone, methyl methacrylate, ethyl benzoate and methyl toluate; phosphites such as triphenyl phosphite and tributyl phosphite; phosphoric acid derivatives such as methyl phosphoric triamide; alkoxy ester compounds; aromatic monocarboxylic acid esters; aromatic alkylalkoxysilanes; aliphatic hydrocarbon alkoxysilanes; various ether compounds; .
- ester compounds such as ⁇ -caprolactone, methyl methacrylate, ethyl benzoate and methyl toluate
- phosphites such as triphenyl phosphite and tributyl phosphite
- phosphoric acid derivatives such as methyl phosphoric triamide
- alkoxy ester compounds aromatic monocarboxylic acid esters
- aromatic alkylalkoxysilanes aromatic alkylalk
- the polymerization method in the above method may be either a batch method or a continuous method, and the polymerization method may be solution polymerization or slurry polymerization using a solvent such as butane, pentane, hexane, heptane, octane, or the like.
- a bulk polymerization method in a monomer or a gas phase polymerization method in a gaseous polymer may be performed using a solvent.
- the method for producing the crystalline propylene-ethylene block copolymer is not particularly limited.
- Propylene-ethylene blocks combined with crystalline propylene homopolymer segments by a step of copolymerizing said crystalline propylene homopolymer segments with ethylene and optionally other ⁇ -olefins. and a second step of obtaining the copolymer portion.
- other ⁇ -olefins include, but are not particularly limited to, propylene, 1-butene, 1-hexene, and the like.
- the polypropylene resin is produced by reacting a polyolefin resin and an ⁇ , ⁇ -unsaturated carboxylic acid or a derivative thereof in the presence or absence of a radical generator at a temperature of 30 to 350° C. in a molten state or in a solution state.
- a known modified (grafted or added with 0.01 to 10% by weight of the ⁇ , ⁇ -unsaturated carboxylic acid or derivative thereof) polyolefin resin obtained by the above-described polypropylene resin and the modified It may be a mixture of polyolefin resins in any ratio.
- modified polyolefin stool The reason for using modified polyolefin stool is to improve the adhesion of the interface between the resin and the filler (filler). By adding the modified polyolefin, the adhesion between the resin and the filler (filler) interface is improved, and the strength can be increased.
- the preferred content ratio of the (Aa) component and the (Abb) component is that the total amount of the (Aa) component and the (Abb) component is 100 parts by mass. Then, the content of component (Aa) is 10 to 70 parts by mass, and the content of component (Abb) is 30 to 90 parts by mass. More preferably, the content of component (Aa) is 10 to 60 parts by mass, the content of component (Abb) is 40 to 90 parts by mass, and more preferably, (Aa ) is 10 to 50 parts by mass, and the content of component (Abb) is in the range of 50 to 90 parts by mass. When the content ratio of the component (Aa) and the component (Abb) is within this range, the impact resistance, heat resistance, and tensile strength are well balanced, which is preferable.
- the ratio of these in the resin composition can be determined by a calibration curve method using Fourier transform infrared spectroscopy (FT-IR).
- FT-IR Fourier transform infrared spectroscopy
- the (Abc) polyphenylene sulfide resin used in the present embodiment is a linear polyphenylene sulfide resin (hereinafter sometimes abbreviated as linear PPS) and a crosslinked polyphenylene sulfide resin (hereinafter, crosslinked It is sometimes abbreviated as PPS.).
- linear PPS linear polyphenylene sulfide resin
- PPS crosslinked polyphenylene sulfide resin
- the former linear PPS is a polymer containing usually 50 mol % or more, preferably 70 mol % or more, more preferably 90 mol % or more of arylene sulfide repeating units represented by the following chemical formula (1).
- Ar represents an arylene group
- examples of the arylene group include a p-phenylene group, an m-phenylene group, and a substituted phenylene group (preferably an alkyl group having 1 to 10 carbon atoms and a phenyl group as the substituent), p,p'-diphenylene sulfone group, p,p'-biphenylene group, p,p'-diphenylenecarbonyl group, naphthylene group and the like.)
- the linear PPS may be a homopolymer having one arylene group as a structural unit, or a copolymer obtained by mixing two or more different arylene groups from the viewpoint of workability and heat resistance. good too.
- a linear PPS having a p-phenylene sulfide repeating unit as a main component is preferable because of its excellent workability and heat resistance and easy industrial availability.
- the production method of this linear PPS is usually a method of polymerizing a halogen-substituted aromatic compound such as p-dichlorobenzene in the presence of sulfur and sodium carbonate, a method of polymerizing sodium sulfide or sodium hydrogen sulfide and sodium hydroxide in a polar solvent. or in the presence of hydrogen sulfide and sodium hydroxide or sodium aminoalkanoate; A method of reacting sodium sulfide and p-dichlorobenzene in a solvent or a sulfone solvent such as sulfolane is preferred.
- a preferred linear PPS has an extraction amount with methylene chloride of 0.7% by mass or less, preferably 0.5% by mass or less, and a terminal -SX group (S is a sulfur atom, X is an alkali metal or hydrogen atom ) is 20 ⁇ mol/g or more, preferably 20 to 60 ⁇ mol/g.
- the extraction amount with methylene chloride can be measured by the following method. After adding 5 g of linear PPS powder to 80 mL of methylene chloride and performing Soxhlet extraction for 6 hours, it is cooled to room temperature and the methylene chloride solution after extraction is transferred to a weighing bottle. Furthermore, the vessel used for the above extraction is washed three times with a total of 60 mL of methylene chloride, and the washings are collected in the weighing bottle. Next, it is heated to about 80° C. to evaporate and remove the methylene chloride in the weighing bottle, and the residue is weighed. You can ask for a percentage.
- the -SX group can be quantified by the following method. That is, after drying the linear PPS powder at 120° C. for 4 hours in advance, 20 g of the dried linear PPS powder was added to 150 g of N-methyl-2-pyrrolidone and vigorously stirred and mixed at room temperature for 30 minutes so as to eliminate powder agglomerates, resulting in a slurry. state. After filtering the slurry, washing is repeated seven times using 1 liter of hot water at about 80° C. each time. The filter cake obtained here is slurried again in 200 g of pure water, and then 1N hydrochloric acid is added to adjust the pH of the slurry to 4.5.
- crosslinked PPS After polymerizing the linear PPS, the crosslinked (including semi-crosslinked) polyphenylene sulfide resin is heat-treated at a temperature below the melting point of the polyphenylene sulfide resin in the presence of oxygen to promote oxidative crosslinking. It has moderately increased polymer molecular weight and viscosity.
- the most preferable one is that the volatile matter collected in the molten state at 320° C. is less than It is a crosslinked PPS of 1000 mass ppm or less.
- the quantification of the volatile matter collected in the 320° C. molten state referred to here can be performed by the following method.
- crosslinked PPS powder 0.5 g was weighed into a sealed test tube having an airflow inlet and an outlet, and immersed in a solder bath heated to 320° C. for 30 minutes while nitrogen gas was supplied from the airflow inlet of the test tube at 100 cc/min.
- the gas containing volatile matter derived from the cross-linked PPS generated in the test tube is purged from the airflow outlet of the test tube, and the purged gas is transferred to a sealed test tube having an airflow inlet and outlet containing acetone. Acetone in the test tube is bubbled from the air flow inlet of the test tube to dissolve the volatile components in the acetone.
- the volatile content of the crosslinked PPS dissolved in acetone was analyzed by a gas chromatograph-mass spectrometer (GC-MS) using a temperature-rising analysis from 50°C to 290°C. Hypothetically quantified, the volatiles in the crosslinked PPS can be determined.
- GC-MS gas chromatograph-mass spectrometer
- these PPS may be acid-modified PPS.
- the acid-modified PPS is obtained by modifying the above PPS with an acid compound.
- Carboxylic acids or anhydrides thereof, saturated aliphatic carboxylic acids, aromatic substituted carboxylic acids, and the like can be mentioned.
- inorganic compound-based acid compounds such as acetic acid, hydrochloric acid, sulfuric acid, phosphoric acid, silicic acid, and carbonic acid can also be mentioned as the acid compound.
- melt viscosity of PPS The melt viscosity at 300° C. of the linear PPS and the crosslinked PPS is 1 to 10,000 Pa ⁇ s, preferably 50 to 8,000 Pa ⁇ s, and more preferably 100 to 5,000 Pa ⁇ s.
- the matrix resin of the present embodiment may contain a polystyrene-based resin.
- Polystyrene resins include atactic polystyrene, rubber-reinforced polystyrene (high impact polystyrene, HIPS), styrene-acrylonitrile copolymer (SAN) having a styrene content of 50% by weight or more, and the styrene-acrylonitrile copolymer. Examples include rubber-reinforced ABS resin and the like, and atactic polystyrene and/or high-impact polystyrene are preferred.
- the above polystyrene-based resins may be used singly or in combination of two or more.
- the polystyrene resin does not include the (Acd) styrene-glycidyl methacrylate copolymer described later.
- the preferred content of (Ac) polystyrene-based resin is 0 to 100 parts by mass when (Aa) polyphenylene ether-based resin is 100 parts by mass, more preferably It is 0 to 90 parts by mass, more preferably 0 to 80 parts by mass.
- (Acb) a block copolymer comprising at least one block mainly composed of aromatic vinyl monomer units and at least one block mainly composed of conjugated diene monomer units; and / or a hydrogenated product of the block copolymer]
- (Acb) block copolymerization comprising at least one block mainly composed of aromatic vinyl monomer units and at least one block mainly composed of conjugated diene monomer units
- Coalescence and/or a hydrogenated product of the block copolymer hereinafter sometimes simply referred to as "(Acb) component
- (Acb) component) may be further included, and preferably included.
- block copolymer containing at least one block mainly composed of aromatic vinyl monomer units and at least one block mainly composed of conjugated diene monomer units and/or the hydrogenated product of the block copolymer includes at least one aromatic vinyl polymer block mainly composed of aromatic vinyl monomer units and at least one block copolymer mainly composed of conjugated diene monomer units.
- aromatic vinyl polymer block "mainly composed of aromatic vinyl monomer units” refers to a block in which 50% by mass or more is aromatic vinyl monomer units.
- the aromatic vinyl monomer unit content is more preferably 70% by mass or more, still more preferably 80% by mass or more, and most preferably 90% by mass or more.
- conjugated diene monomer unit content is more preferably 70% by mass or more, still more preferably 80% by mass or more, and most preferably 90% by mass or more.
- the aromatic vinyl polymer block may be, for example, a copolymer block in which a small amount of conjugated diene compound is randomly bonded to the aromatic vinyl polymer block.
- the conjugated diene polymer block described above for example, it may be a copolymer block in which a small amount of an aromatic vinyl compound is randomly bonded to the conjugated diene polymer block.
- the aromatic vinyl compound used to form the aromatic vinyl monomer unit is not particularly limited, and examples thereof include styrene, ⁇ -methylstyrene, vinyltoluene, etc., and one or more selected from these. Compounds are used, of which styrene is particularly preferred.
- the conjugated diene compound used to form the conjugated diene polymer block is not particularly limited, and examples thereof include butadiene, isoprene, piperylene, 1,3-pentadiene, etc., and one or more compounds selected from these. are used, but butadiene, isoprene and combinations thereof are preferred.
- the microstructure of the conjugated diene polymer block portion of the block copolymer has a 1,2-vinyl content or a total amount of 1,2-vinyl content and 3,4-vinyl content (total vinyl bond content) of 5 to It is preferably 85%, more preferably 10-80%.
- the total vinyl bond content can be measured using an infrared spectrophotometer.
- the non-hydrogenated block copolymer used for producing the hydrogenated product of the above block copolymer is an aromatic vinyl polymer block (A) and a conjugated diene polymer block (B) It is preferably a block copolymer having a bond type selected from AB type, ABA type and ABAB type. Among these, block copolymers having different bond types may be used in combination. Among these, it is more preferable to have a binding form selected from ABA type and ABAAB type, and more preferably to have an ABA type binding form.
- the (Acb) component used in the present embodiment is preferably a partially hydrogenated block copolymer (partially hydrogenated block copolymer).
- Partially hydrogenated block copolymer means that the aliphatic double bond of the conjugated diene polymer block is controlled in the range of more than 0% and less than 100% by hydrogenating the above-mentioned non-hydrogenated block copolymer. What you did.
- the hydrogenation rate of the partially hydrogenated block copolymer is preferably 50% or more and less than 100%, more preferably 80% or more and less than 100%, and most preferably 98% or more and less than 100%.
- the (Acb) component used in this embodiment preferably has a number average molecular weight of 30,000 or more and less than 300,000. Within this range, a composition having excellent fluidity, impact strength, and flame retardancy can be obtained.
- the method for evaluating the number average molecular weight of the (Acb) component in the resin composition is shown below. That is, using a solvent, such as chloroform, which shows good solubility in the (Acb) component and shows poor solubility in the (Aa) polyphenylene ether-based resin, the (Acb) component to fractionate. This was measured using a gel permeation chromatography measuring device [GPC SYSTEM21: manufactured by Showa Denko Co., Ltd.] with an ultraviolet spectroscopic detector [UV-41: manufactured by Showa Denko Co., Ltd.], and converted with standard polystyrene. to determine the number average molecular weight.
- a solvent such as chloroform
- the measurement conditions may be as follows [solvent: chloroform, temperature: 40 ° C., column: sample side (KG, K-800RL, K-800R), reference side (K-805L x 2), flow rate 10 mL/min, measurement wavelength: 254 nm, pressure 15-17 kg/cm 2 )].
- solvent chloroform
- column sample side (KG, K-800RL, K-800R), reference side (K-805L x 2), flow rate 10 mL/min, measurement wavelength: 254 nm, pressure 15-17 kg/cm 2 )
- the said low molecular weight component shall point out the component with a molecular weight of 3000 or less.
- the correct calculated molecular weight distribution is in the range of 1.0 to 1.1.
- Block copolymers as the (Acb) component that can be used in the present embodiment have different bond types and aromatic vinyl compound species, as long as they do not contradict the gist of the present embodiment. Different types, different types of conjugated diene compounds, different 1,2-bonded vinyl contents or different 1,2-bonded vinyl contents and 3,4-bonded vinyl contents, different aromatic vinyl compound component contents 2 or more of each of those having different hydrogenation rates may be mixed and used.
- block copolymers as the (Acb) component that can be used in the present embodiment may be wholly or partially modified block copolymers.
- the modified block copolymer as used herein means at least one carbon-carbon double bond or triple bond and at least one carboxylic acid group, acid anhydride group, amino group, hydroxyl group or It refers to a block copolymer modified with at least one modifying compound having glycidyl groups.
- the method for producing the modified block copolymer includes (1) melt kneading with a modifying compound in a temperature range of 250° C. or less from the softening point temperature of the block copolymer in the presence or absence of a radical initiator; (2) a method of reacting the block copolymer and the modifying compound in a solution at a temperature below the softening point of the block copolymer; (3) a method of reacting the block copolymer with a modifying compound at a temperature below the softening point of the block copolymer Examples include a method of reacting the block copolymer and the modified compound without melting, and the like, and any of these methods may be used, but the method of (1) is preferable, and among the methods of (1), the method is performed in the presence of a radical initiator.
- the preferred content of the component (Acb) is 1 to 40 parts by mass, more preferably 2 to 40 parts by mass when the (Aa) polyphenylene ether resin is 100 parts by mass. 35 parts by mass, more preferably 2 to 30 parts by mass.
- the total content with component cb) is preferably 20% by mass or more, preferably 25% by mass or more, and more preferably 30% by mass or more.
- the thermoplastic resin composition of the present embodiment includes a copolymer of ethylene and an ⁇ -olefin other than ethylene (ethylene- ⁇ -olefin copolymer: hereinafter simply referred to as "(A-c-c) component" ) can be included. From the viewpoint of the chemical resistance and impact resistance of the resulting resin composition, it is preferable that the monomer units constituting the component (Acc) do not contain propylene units.
- the phrase "not including a propylene unit" in "an olefin-based polymer composed of an olefin” includes cases in which propylene is included as a structural unit to an extent that does not impair the effects of the invention. ) means that the content of propylene units in all structural units constituting component (Acc) in component is less than 0.1% by mass.
- Examples of the (Acc) component include copolymers of ethylene and one or more C3-C20 ⁇ -olefins. Among them, copolymers of ethylene and one or more C3-C8 ⁇ -olefins are more preferable, and ethylene and 1-propylene, 1-butene, 1-hexene, 4-methyl- It is more preferably a copolymer with one or two or more comonomers selected from the group consisting of 1-pentene and 1-octene, and particularly preferably a copolymer of ethylene and 1-butene. . By using such a copolymer as the (Acc) component, there is a tendency to obtain a resin composition having higher impact resistance and higher chemical resistance.
- the (Acc) components may be used singly or in combination of two or more. Also, two or more ethylene- ⁇ -olefin copolymers may be used as the component (c).
- the content of ethylene in the component (Acc) is preferably 5 to 95% by mass, more preferably 30 to 90% by mass, based on the total amount of the olefin polymer. %.
- the content of ⁇ -olefins other than ethylene in the component (Acc) is not particularly limited, and from the viewpoint of the flexibility of the resin composition, it is 5% by mass or more with respect to the total amount of the olefin polymer. It is preferably 20% by mass or more, more preferably 20% by mass or more, and from the viewpoint of rigidity of the resin composition, preferably 50% by mass or less, more preferably 48% by mass or less.
- the embrittlement temperature of the component (Acc) is -50°C or less, and from the viewpoint of obtaining even better impact resistance and chemical resistance, it is preferably -60°C or less, and -70°C. The following are more preferable.
- the embrittlement temperature can be measured according to ASTM D746.
- the thermoplastic resin composition of the present embodiment may contain (Acd) styrene-glycidyl methacrylate copolymer (hereinafter sometimes simply referred to as "(Acd) component").
- the (Acd) component acts as a miscibility agent between the (Aa) polyphenylene ether resin and the (Abc) polyphenylene sulfide resin.
- Component (Acd) may contain other monomer components as long as it is a copolymer containing styrene and glycidyl methacrylate as monomer components, but the sum of the structure derived from styrene and the structure derived from glycidyl methacrylate Copolymers with a content of 65 to 100% by weight are preferred.
- the content is more preferably 75 to 100% by mass, and may be 100% by mass.
- the (Acd) component preferably contains 0.3 to 20% by mass, more preferably 1 to 15% by mass, and even more preferably 3 to 10% by mass of a structure derived from glycidyl methacrylate.
- thermoplastic resin composition of the present embodiment in addition to the components described above, an inorganic filler can be added at any stage as necessary. Adding an inorganic filler suppresses dimensional change at high temperatures.
- Inorganic fillers include glass fiber, potassium titanate fiber, gypsum fiber, brass fiber, ceramic fiber, boron whisker fiber, mica, talc, silica, calcium carbonate, kaolin, calcined kaolin, wollastonite, xonotlite, apatite, and glass.
- Examples include fibrous, granular, plate-like, and needle-like inorganic reinforcing materials such as beads, glass flakes, and titanium oxide, and it is particularly preferable to use fillers with low anisotropy.
- These inorganic fillers can be used in combination of two or more. Among these, more preferred inorganic fillers include glass fiber, carbon fiber and glass beads.
- the inorganic filler may be surface-treated by a known method using a surface treatment agent such as a silane coupling agent.
- a surface treatment agent such as a silane coupling agent.
- natural ore-based fillers often contain a small amount of elemental iron, so it is necessary to select and use fillers from which elemental iron has been removed by refining.
- a specific preferred content of each inorganic filler is 10% by mass or more, more preferably 15% by mass or more, and still more preferably 100% by mass of the entire thermoplastic resin composition. It is 20% by mass or less.
- the preferred content of the inorganic filler as a whole is preferably 10% by mass or more, more preferably 20% by mass or more, more preferably 30% by mass, when the entire thermoplastic resin composition is 100% by mass. % by mass or more is more preferable.
- the method for coloring the resin composition is not particularly limited, and one or more coloring agents selected from known organic dyes and pigments and inorganic pigments can be used.
- organic dyes and pigments examples include azo lake pigments, benzimidazolone pigments, diarylide pigments, condensed azo pigments, and other azo pigments; phthalocyanine blue, phthalocyanine green, and other phthalocyanine pigments; isoindolinone pigments; , perylene pigments, anthraquinone pigments, perinone pigments, condensed polycyclic pigments such as dioxazine violet, azine pigments, and carbon black.
- the carbon black has a dibutyl phthalate (DBP) absorption of less than 250 mL/100 g, preferably less than 150 mL/100 g, and a nitrogen adsorption specific surface area of less than 900 m 2 /g, more preferably less than 400 m 2 /g. is preferred. When these are in this range, it is possible to obtain a composition particularly excellent in colorability, mechanical strength and flame retardancy.
- the DBP absorption amount and nitrogen adsorption specific surface area referred to herein are values measured by the methods defined in ASTM D2414 and JIS K6217, respectively.
- Examples of azine-based dyes include Solvent Black 5 (CI 50415, CAS No. 11099-03-9) and Solvent Black 7 (CI 50415: 1, CAS No. 8005-20-5) in Color Index. /101357-15-7) and Acid Black 2 (CI 50420, CAS No. 8005-03-6/68510-98-5).
- inorganic pigments include metal oxides other than iron oxide, such as titanium oxide, zinc oxide, and chromium oxide, and composite metal oxides such as titanium yellow, cobalt blue, and ultramarine blue.
- the preferred content of the colorant is 2% by mass or less for carbon black, 2% by mass or less for azine-based dyes, and 8% by mass or less for inorganic pigments when the entire resin composition is taken as 100% by mass. More preferable amounts are 1% by mass or less for carbon black, 1% by mass or less for azine dyes, and 5% by mass or less for inorganic pigments.
- the resin composition of the present embodiment includes (C) other components such as a plasticizer (low molecular weight polyolefin, polyethylene glycol, fatty acid esters, etc.), an antistatic agent, a nucleating agent, and a fluidity improver. , reinforcing agents, various peroxides, spreading agents, copper heat stabilizers, organic heat stabilizers represented by hindered phenol antioxidants, antioxidants, UV absorbers, light stabilizers, ethylene Lubricants such as bis-stearic acid amide, modifiers such as maleic anhydride, and the like can be included.
- the specific preferred content of each of the other components is 15% by mass or less, more preferably 13% by mass or less, and still more preferably, when the total resin composition is 100% by mass. is 10% by mass or less.
- the preferred content of the other component (C) as a whole is preferably 30% by mass or less, more preferably 25% by mass or less, when the entire resin composition is 100% by mass. It is more preferably 20% by mass or less.
- thermoplastic resin composition ⁇ Characteristics of thermoplastic resin composition> The properties of the thermoplastic resin composition of this embodiment are described below.
- the deflection temperature under load (DTUL) (°C) of the thermoplastic resin composition of the present embodiment As the deflection temperature under load (DTUL) (°C) of the thermoplastic resin composition of the present embodiment, it becomes a larger value, so that it can be deformed even when the heat generated by the base station increases as the speed of communication increases. It is preferable from the viewpoint that it becomes difficult to A specific DTUL is 120° C. or higher, preferably 130° C. or higher, and more preferably 140° C. or higher.
- the deflection temperature under load (DTUL) is a value measured by the method described in Examples below.
- the dielectric loss tangent of the thermoplastic resin composition of the present embodiment has a smaller value because it indicates a reduction in the energy loss rate.
- the dielectric loss tangent is a value measured by the method described in Examples below.
- the temperature dependence of the dielectric loss tangent at 28 GHz of the thermoplastic resin composition satisfies the following conditions, the low dielectric loss tangent can be maintained even when the heat generated by the base station increases as the speed of communication increases. It is preferable from the viewpoint of being able to 1.
- the DTUL is 120° C. or more and less than 140° C.
- the difference between the dielectric loss tangent at 23° C. and the dielectric loss tangent at 120° C. is 0.004 or less.2.
- the DTUL is 140°C or higher, the difference between the dielectric loss tangent at 23°C and the dielectric loss tangent at 140°C is 0.004 or less.
- the above range can be adjusted by including a thermoplastic resin having a high glass transition temperature, such as (Aa) polyphenylene ether resin.
- thermoplastic resin composition used for the antenna member of the present embodiment divides the temperature when raising the temperature from -30 ° C. to 120 ° C. into temperature ranges of 10 ° C., and the low temperature of two adjacent temperature ranges
- the side is the low temperature range
- the high temperature side is the high temperature range
- high temperature expansion coefficient in the TD direction of the resin composition measured by the method described in ISO 11359 in the high temperature range mm / mm / ° C.
- the metal coating tends to be difficult to peel off due to temperature change, and deformation of the part itself due to temperature change can be suppressed.
- the above relationship is -45 ⁇ ((high temperature expansion coefficient - low temperature expansion coefficient) / low temperature expansion coefficient) ⁇ 100 ⁇ 45 is more preferably -40 ⁇ ((high temperature expansion coefficient - low temperature expansion coefficient) / low temperature expansion coefficient) ⁇ 100 ⁇ 40 is more preferable.
- the above temperature range is -30°C to 120°C, -30°C to -20°C, -20°C to -10°C, -10°C to 0°C, . , refers to the temperature range divided into 15.
- Two adjacent temperature ranges refer to any one of 14 combinations of two adjacent temperature ranges among the 15 divided temperature ranges. The above relationship is satisfied in all combinations (14 combinations) of two adjacent temperature ranges selected from 15 divided temperature ranges. Note that the expansion coefficient in the TD direction of the resin composition measured by the method described in ISO 11359 was measured using a test piece prepared by the method described in Examples below under the conditions described in Examples below. shall mean the value to be measured.
- thermoplastic resin composition By including polyphenylene ether, which is an amorphous thermoplastic resin with a high glass transition temperature, in the thermoplastic resin composition, it is possible to reduce the variation in the expansion coefficient between adjacent temperature ranges, and the expansion coefficient can be reduced. Relationships can be adjusted.
- the average value of the expansion coefficient in the TD direction measured by the method described in ISO 11359 in each temperature range in which the temperature is divided into 15 for each 10 ° C when the temperature is increased from -30 ° C to 120 ° C (15
- the average value of the expansion coefficient values which may be referred to as "average expansion coefficient" in this specification) is preferably 10 ⁇ 10 -5 mm/mm/°C or less from the viewpoint of suppressing peeling of the plating. It is more preferably 9 ⁇ 10 ⁇ 5 mm/mm/° C. or less, still more preferably 8 ⁇ 10 ⁇ 5 mm/mm/° C. or less.
- the average value can be set within the above range by using a resin having a low expansion coefficient and by adjusting the type and blending amount of the inorganic filler.
- the thermoplastic resin composition of the present embodiment has a TD measured by the method described in ISO 11359 in the above temperature range, in which the temperature is increased from -30 ° C. to 120 ° C. by dividing the temperature into 15 for each 10 ° C.
- the maximum directional expansion coefficient is preferably 10 ⁇ 10 ⁇ 5 mm/mm/°C or less, more preferably 2 ⁇ 10 ⁇ 5 mm/mm/°C to 8 ⁇ 10 ⁇ 5 mm/mm/°C. is. When the maximum value is 10 ⁇ 10 ⁇ 5 mm/mm/° C.
- the maximum value can be set within the above range by using a resin having a low expansion coefficient and by adjusting the type and blending amount of the inorganic filler.
- the resin composition of the present embodiment can be produced by melt-kneading each component constituting component (A) and, if necessary, a colorant, an inorganic filler, and other components.
- the melt-kneader for melt-kneading is not limited to the following, but for example, a single-screw extruder, a multi-screw extruder including a twin-screw extruder, a roll, a kneader, a Brabender plastograph, a Banbury mixer, etc.
- Heat melt-kneading A twin-screw extruder is particularly preferable from the viewpoint of kneadability.
- the ZSK series manufactured by WERNER & PFLEIDERER the TEM series manufactured by Toshiba Machine Co., Ltd.
- the TEX series manufactured by The Japan Steel Works, Ltd., and the like can be mentioned.
- the melt-kneading temperature at this time can be selected from a temperature at which a crystalline resin can be heated and melted at a temperature above the melting point of the crystalline resin, and a non-crystalline resin at a temperature above the glass transition temperature, which can be easily processed. It can be arbitrarily selected from 200 to 370°C.
- the L/D (effective barrel length/barrel inner diameter) of the extruder is preferably 20 or more and 60 or less, more preferably 30 or more and 50 or less.
- the configuration of the extruder is not particularly limited, but for example, with respect to the flow direction of the raw material, there is a first raw material supply port on the upstream side, a first vacuum vent downstream from the first raw material supply port, and the first vacuum vent.
- a second raw material supply port is provided downstream (if necessary, a third and fourth raw material supply port may be further provided downstream of the second raw material supply port), and further downstream of the second raw material supply port
- a second vacuum vent is preferred.
- a kneading section is provided upstream of the first vacuum vent
- a kneading section is provided between the first vacuum vent and the second raw material supply port
- a kneading section is provided between the second to fourth raw material supply ports and the second vacuum vent. More preferably, a kneading section is provided between them.
- the method of supplying raw materials to the second to fourth raw material supply ports is not particularly limited.
- a method of feeding using a forced side feeder from the mouth is preferred because it tends to provide more stable feeding.
- the raw material contains powder and it is desired to reduce the generation of crosslinked products and carbonized products due to the heat history of the resin
- a method using a forced side feeder to supply from the extruder side is more preferable. It is more preferable to provide a fourth raw material supply port and divide and supply these raw material powders.
- liquid raw materials it is preferable to add them into an extruder using a plunger pump, gear pump, or the like.
- the upper openings of the second to fourth raw material supply openings of the extruder can also be used as openings for removing the air that is conveyed together.
- the melt-kneading temperature and screw rotation speed in the melt-kneading step of the resin composition are not particularly limited, but the crystalline resin is heated at the melting point temperature or higher of the crystalline resin, and the amorphous resin is heated at the glass transition temperature or higher.
- a temperature at which the material can be melted and processed without difficulty can be selected, and is usually selected arbitrarily from 200 to 370° C., and the screw rotation speed is set to 100 to 1200 rpm.
- each component constituting component (A), raw titanium dioxide is added to the first It is supplied to the raw material supply port, the heating and melting zone is set to the melting temperature of the thermoplastic resin, and melt-kneaded at a screw rotation speed of 100 to 1200 rpm, preferably 200 to 500 rpm, and melt-kneaded.
- each component constituting component (A) and the raw material titanium dioxide may be supplied to the twin-screw extruder from the first raw material supply port of the extruder collectively as described above.
- a raw material supply port, a third raw material supply port, and a fourth raw material supply port may be provided to supply each component separately.
- the oxygen concentration in each process line in the addition route of each raw material to the extruder is kept below 1.0% by volume.
- the addition route is not particularly limited, but a specific example includes, in order from the stock tank, a pipe, a gravimetric feeder having a refill tank, a pipe, a supply hopper, and a twin-screw extruder.
- the method for maintaining such a low oxygen concentration is not particularly limited, but a method of introducing an inert gas into individual process lines with improved airtightness is effective. Generally, it is preferable to introduce nitrogen gas to maintain the oxygen concentration at less than 1.0% by volume.
- the resin composition of the present embodiment is extruded through a twin-screw extruder.
- the resin composition of the present embodiment has the effect of further reducing the residue in the screw of the twin-screw extruder, and furthermore, in the resin composition obtained by the above-described production method, it reduces the occurrence of black spot foreign matter, carbides, etc. effect.
- an extruder in which the oxygen concentration of each raw material supply port is controlled to less than 1.0% by volume is used, and any one of the following methods 1 to 3 is performed. preferably.
- the total amount of each component constituting the component (A) contained in the resin composition of the present embodiment is melt-kneaded (first kneading step), and the molten kneaded product obtained in the first kneading step is added to the raw material dioxide.
- first kneading step melt-kneaded
- second kneading step melt-kneading step
- the total amount of each component constituting the component (A) contained in the resin composition of the present embodiment and part of the raw material titanium dioxide are melt-kneaded (first kneading step), and the molten state obtained in the first kneading step is A production method in which the remaining amount of raw material titanium dioxide is supplied to the kneaded product, followed by melt-kneading (second kneading step). 3.
- thermoplastic resins such as (Aa) polyphenylene ether-based resins and raw material titanium dioxide contained in component (A) are in the form of powder, and are poorly chewed into the extruder. It is difficult to increase the production of Furthermore, the residence time of the resin in the extruder is long, so thermal deterioration is likely to occur.
- the resin compositions obtained by the above production methods 1 and 2 have improved biting properties of titanium dioxide and excellent mixing properties of each component compared to the resin compositions obtained by the production method 3. , It is possible to reduce the decomposition due to thermal deterioration, the generation of crosslinked products and carbides, and the production amount of the resin per hour can be increased, so that a resin composition with excellent productivity and quality can be obtained. preferable.
- injection molding, antenna member The injection molded article of this embodiment is made of the thermoplastic resin composition described above.
- the method for producing the injection molded article of the present embodiment is not particularly limited except that it is injection molding.
- injection foam molding can be performed to further reduce the weight. It is effective for both chemical foaming and physical foaming, and can contribute to weight reduction.
- the injection molded body manufactured by such a method is used in a form in which a metal coating is formed on the surface.
- the antenna member of this embodiment has one or more of the above injection molded bodies.
- the antenna member may have a structure in which a plurality of molded products are fitted.
- the antenna member of this embodiment has the injection molded body, it can be easily applied to parts that require plating and are exposed to high temperatures, such as antenna filters and antenna elements (pendulums), among other antenna parts.
- a method for metal-coating at least a portion of the antenna member is not particularly limited, and a conventionally known method can be used.
- a metal coating can be formed on the insulating layer by dry plating or wet plating.
- the surface of the injection molded body is first treated with an oxidizing agent such as permanganate (potassium permanganate, sodium permanganate, etc.), dichromate, ozone, hydrogen peroxide/sulfuric acid, or nitric acid. is roughened (etched) to form uneven anchors.
- a sodium hydroxide aqueous solution such as potassium permanganate or sodium permanganate is preferably used.
- a metal coating is then formed by a combination of electroless and electrolytic plating. It is also possible to form a plating resist having a pattern opposite to the pattern to be coated with metal, and to form the metal coating only by electroless plating.
- a method for subsequent pattern formation for example, a subtractive method, a semi-additive method, or the like known to those skilled in the art can be used.
- PVD method Physical vapor deposition method
- CVD method chemical vapor deposition method
- liquid phase growth method etc.
- PVD methods include vacuum deposition methods, molecular beam epitaxy methods (MBE methods), sputtering methods, ionization deposition methods, laser ablation methods, ion cluster beam methods, and the like.
- MBE methods molecular beam epitaxy methods
- CVD method phase vapor deposition method
- MOCVD method organic metal CVD method
- CVT method chemical transport method
- Examples include an epitaxy method, a traveling solvent method, and a source current control method.
- Other methods include an electroless plating method and the like.
- the vacuum deposition method, the sputtering method, and the plasma CVD method are preferred from the viewpoints of film thickness control, film quality control, versatility, productivity, and the like.
- the vacuum deposition method is a method of heating and evaporating a target for forming a film with an electron beam or a resistance heater to deposit a film on a substrate. After reducing the initial degree of vacuum during vapor deposition to 1 ⁇ 10 ⁇ 2 Pa or less, preferably 1 ⁇ 10 ⁇ 3 Pa or less, vapor deposition is preferably carried out at 0.5 to 100 ⁇ /sec.
- high kinetic energy particles such as argon ions supplied by a non-thermal equilibrium glow discharge plasma atmosphere or an ion beam from an ion source collide with a target used for a film to obtain emitted particles from the target, which are deposited on a substrate. It is a method of filming.
- the plasma CVD method is widely used as a method for forming a hydrogenated amorphous Si film.
- a method of decomposing silane (SiH 4 ) gas by high-frequency glow discharge and depositing it on a substrate Total pressure during discharge 0.1 to 1 torr (13 to 130 Pa), gas concentration 10% or more when diluted with argon or hydrogen, gas flow rate 50 to 200 mL/min, input power several tens to several hundred mW/cm 2 .
- the metal used for the metal coating in this embodiment is not particularly limited, it is preferable to use, for example, copper or gold with high conductivity.
- the antenna member of this embodiment may be used after being coated with metal ink or plated.
- the antenna member of this embodiment may have one or more selected from the group consisting of metal circuits, metal wiring, and metal substrates.
- an injection-molded article to which metal ink can be applied is preferably used as the injection-molded article of the present embodiment.
- metal inks gold, silver, or copper can be used.
- inks containing multiple metals can also be used.
- any metal can be used. Copper is preferred from the standpoint of conductivity, but lead, tin, gold and silver can also be used. Since the antenna member of the present embodiment has a high copper damage prevention property and tends to have a low water absorption rate, it is possible to reduce cracks after the metal ink is applied or plated.
- the antenna member of this embodiment can also be used in a method that requires heat resistance, such as a method that uses a laser for adhesion.
- an inkjet method can be used for the antenna member, and a conductive metal paste can be used to draw and form a circuit pattern on the wiring board.
- This circuit pattern formation method may be based on a known method (see, for example, Japanese Patent Application Laid-Open No. 2002-324966).
- the conductive metal paste to be used is a conductive metal paste obtained by uniformly dispersing ultrafine metal particles having a fine average particle size in a thermosetting resin composition containing an organic solvent.
- the ultrafine metal particles are selected to have an average particle diameter in the range of 1 to 100 nm, and the surface of the ultrafine metal particles contains nitrogen and oxygen as groups capable of coordinative bonding with the metal elements contained in the ultrafine metal particles.
- coated with one or more compounds having a group containing a sulfur atom can be preferably used.
- the metal ultrafine particles having a fine average particle size contained in the conductive metal paste include gold, silver, copper, platinum, palladium, tungsten, nickel, tantalum, bismuth, lead, indium, tin, zinc, titanium, Fine particles made of one kind of metal selected from the group consisting of aluminum, or fine particles of an alloy made of two or more kinds of metals can be preferably used.
- a method of forming a circuit pattern includes a step of spraying and applying the conductive metal paste as fine droplets onto a substrate to draw a circuit pattern made of a coating film of the conductive metal paste; and heat-treating the coating film of the metal paste at a temperature at which at least the thermosetting resin is thermally cured.
- Inkjet drawing means include thermal drawing means that generate bubbles by heating and foaming and discharge droplets, and piezo drawing means that discharges droplets by compression using a piezo element. .
- the antenna member of this embodiment can be used for applications requiring a material with a low dielectric loss tangent, especially in a high frequency region. In this application, if the loss becomes large, the performance as a component for communication equipment deteriorates, so control of the dielectric loss tangent becomes an important technology. According to the present embodiment, it is possible to provide an antenna member formed by injection molding, which has little dimensional change and dielectric loss tangent change in a high-temperature region while maintaining adhesion to the metal film.
- the antenna member of this embodiment can handle information of all frequencies from low frequencies to high frequencies, it can be used as a filter or an antenna element (pendulum part) of an antenna for communication equipment.
- it can be used in a heavy antenna base station for outdoor or indoor use because it can exhibit these properties even in a low-temperature, high-temperature or wet environment while maintaining various characteristics.
- Aa polyphenylene ether (hereinafter, PPE)
- A-a-1) Polyphenylene ether resin obtained by oxidative polymerization of 2,6-xylenol
- the reduced viscosity of the polyphenylene ether resin (0.5 g/dL, chloroform solution, measured at 30° C.) is 0.52 dL/ was g.
- Tg was about 210°C.
- A-a-2) Polyphenylene ether resin obtained by oxidative polymerization of 2,6-xylenol
- the reduced viscosity of the polyphenylene ether resin (0.5 g/dL, chloroform solution, measured at 30° C.) is 0.40 dL/ was g. Tg was about 210°C.
- the autoclave was pressurized to 22 kg/cm@2. After continuing the reaction for 1 hour, the temperature was raised to 230°C, and then the temperature was maintained at 230°C for 2 hours, and the reaction was carried out while gradually removing water vapor and maintaining the pressure at 22 kg/cm 2 . Next, the pressure was lowered to 10 kg/cm 2 over 30 minutes, and the reaction was further continued for 1 hour to obtain a prepolymer having an intrinsic viscosity [ ⁇ ] of 0.25 dl/g. This was dried at 100° C. under reduced pressure for 12 hours and pulverized to a size of 2 mm or less. This was solid phase polymerized at 230° C.
- the terminal amino group concentration was 20 ⁇ mol/g as a result of measurement according to the method for measuring the amino group terminal concentration described in Examples of JP-A-7-228689. Tg was about 125°C.
- (Abb) polypropylene (Abb-1) polypropylene MFR 2 g/10 minutes polypropylene homopolymer MFR is based on ISO 1133, temperature 230 ° C., load 2.16 kg conditions measured in Tg was about 0°C. (Abb-2) Maleic anhydride-modified polypropylene having a number average molecular weight (Mn) of 60,000 and a weight average molecular weight (Mw) of 91,000. Tg was about 0°C.
- (Acb) a block copolymer comprising at least one block mainly composed of aromatic vinyl monomer units and at least one block mainly composed of conjugated diene monomer units, and/or , Hydrogenated product of the block copolymer (Acb-1) Hydrogenated block copolymer (manufactured by Asahi Kasei Corporation Tuftec (trademark) H1051) (Acb-2) Hydrogenated block copolymer (manufactured by Asahi Kasei Corporation Tuftec (trademark) H1081) (Acb-3)
- a block copolymer having a block structure of II-I-II was synthesized by a known method, with polymer block I consisting of polystyrene and polymer block II consisting of polybutadiene.
- the synthesized block copolymer was hydrogenated by a known method. No modification of the polymer was performed.
- the physical properties of the obtained unmodified hydrogenated block copolymer are shown below.
- B Inorganic filler (B-1) Glass fiber (manufactured by Nippon Electric Glass Co., Ltd. ECS03-T249) (B-2) Glass fiber (manufactured by Nippon Electric Glass Co., Ltd. ECS03-T747) (B-3) Glass fiber (manufactured by Nippon Electric Glass Co., Ltd.
- C-1 Ethylene bis stearamide (manufactured by Kao Corporation “Kaowax EB-G”)
- C-2) Maleic anhydride (manufactured by NOF Corporation, "Crystal MAN”)
- C-3) Peroxide manufactured by NOF Co., Ltd., "Perhexa 25B-40
- Measuring device vector network analyzer HP8510C (Agilent Technologies) synthesized sweeper HP83651A (same as above) test set HP8517B (same as above)
- Specimen dimensions 40 mm x 4 mm x 2.0 mm
- Shape of resonator cylinder with inner diameter of 229 mm and height of 40 mm
- Measurement direction 1 direction
- Measurement frequency around 1 GHz (TM010 mode)
- Pretreatment 90h/22 ⁇ 1°C/60 ⁇ 5%RH
- Test environment 22°C/56% RH It was determined that the lower the dielectric loss tangent, the better the performance.
- Measurement frequency 22GHz-33GHz Measurement method: Frequency change method
- Measurement equipment Vector network analyzer (KeysightPNA N5247B 10MHz-67GHz), Keycom high frequency free space type S parameter measurement jig, control PC
- Measurement environment conditions room temperature 26°C, humidity 50% (1-5) Dielectric loss tangent after water absorption
- Pellets of the obtained resin composition are supplied to a small injection molding machine (trade name: EC75-SXII, manufactured by Toshiba Machine Co., Ltd.) set at a cylinder temperature of 250 to 350 ° C., A flat plate of 60 mm x 60 mm x 0.9 mm was prepared under the conditions of a mold temperature of 70 to 130 ° C., an injection pressure of 200 MPa, an injection time of 20 seconds, and a cooling time of 20 seconds. was measured at 10 GHz.
- Measurement frequency 10GHz Measurement equipment: 10MHz to 43.5GHz
- Deflection temperature under load The obtained pellets of the resin composition are supplied to a small injection molding machine (trade name: EC75-SXII, manufactured by Toshiba Machine Co., Ltd.) set to a cylinder temperature of 250 to 350 ° C., a mold temperature of 70 to 130 ° C., and an injection pressure. 200 MPa, injection time of 20 seconds, cooling time of 15 seconds, an ISO dumbbell for evaluation was produced under the conditions and mold conforming to the ISO dumbbell molding conditions. Also, the ISO dumbbell was cut to prepare a test piece for measurement of deflection temperature under load (DTUL). Deflection temperature under load: DTUL (ISO 75: 1.80 MPa load) was measured using the test piece for measuring deflection temperature under load. It was determined that the larger the value, the better the heat resistance.
- the pellets of the obtained resin composition are supplied to a small injection molding machine (trade name: EC75-SXII, manufactured by Toshiba Machine Co., Ltd.) set at a cylinder temperature of 250 to 350 ° C., and the mold temperature is 70 to 70.
- a flat plate of 90 mm ⁇ 50 mm ⁇ 2.5 mm was produced under conditions of 130° C., injection pressure of 200 MPa, injection time of 20 seconds, and cooling time of 15 seconds.
- the flat plate was etched with chromic acid and then plated with electroless copper. At this time, ⁇ indicates that the plate was plated on the entire surface, and x indicates that the plate was not plated. Furthermore, after performing a heat cycle test on the plating between -30 ° C.
- the pellets of the obtained resin composition are supplied to a small injection molding machine (trade name: EC75-SXII, manufactured by Toshiba Machine Co., Ltd.) set at a cylinder temperature of 250 to 350 ° C., A flat plate of 60 mm ⁇ 60 mm ⁇ 0.9 mm was produced under conditions of a mold temperature of 70 to 130° C., an injection pressure of 250 MPa, an injection time of 20 seconds, and a cooling time of 15 seconds. The flat plate was cut into a size of 37 mm ⁇ 37 mm ⁇ 0.9 mm, and the dielectric loss tangent was measured using the following device. At this time, in the case of materials with a DTUL of 120° C. or higher and 140° C.
- Expansion rate The pellets of the obtained resin composition are supplied to a small injection molding machine (trade name: EC75-SXII, manufactured by Toshiba Machine Co., Ltd.) set at a cylinder temperature of 250 to 350 ° C., and the mold temperature is 70 to 70. 130° C., injection pressure of 200 MPa, injection time of 20 seconds, cooling time of 15 seconds, an ISO dumbbell for evaluation was produced under the conditions and mold conforming to the ISO dumbbell molding conditions.
- a test piece was cut out from the ISO dumbbell as shown in FIG. (TMA, trade name TMA/SS6100, manufactured by SII Technology) was used to measure the expansion rate under the following conditions.
- the expansion coefficient of the low temperature range (low temperature range expansion (mm/mm/°C)) and the coefficient of expansion in the high temperature region (coefficient of expansion in the high temperature region (mm/mm/°C))
- the following formula is used to determine the ratio between the low temperature region and the high temperature region. The rate of change in expansion rate was obtained, and the value with the largest rate of change was taken as the maximum value (%) of the rate of change.
- any two adjacent temperature ranges are defined as 15 temperature ranges (-30°C to -20°C, -20°C to -10°C, -30°C to -20°C, -20°C to -10°C, -10 ° C to 0 ° C, ..., 110 ° C to 120 ° C), 14 types of combinations of adjacent temperature ranges C., a combination of a low temperature range of -20.degree. C. to -10.degree. C. and a high temperature range of -10.degree. C. to 0.degree.
- Antenna Efficiency at High and Low Temperatures Antenna efficiency was simulated under the following conditions.
- Antenna base material 60 ⁇ 7 ⁇ 1 mm 3 , all-surface solid GND, pattern width 1 mm, thickness 25 ⁇ m.
- Copper + Ni plating Main substrate 60 ⁇ 130 ⁇ 1mm 3 , Relative permittivity 4.0
- ⁇ High temperature range> The following values were used depending on the DTUL value of the material. Dielectric properties at 100°C for materials with a DTUL of 120°C or less Dielectric properties at 120°C for materials with a DTUL between 120°C and 140°C Dielectric properties ⁇ Low temperature range> Dielectric properties at ⁇ 30° C. were used. A total efficiency of 4 GHz was obtained from the simulation, and the total efficiency was taken as the antenna efficiency. The closer the total efficiency is to 0, the better, and it can be said that the performance as an antenna is high.
- thermoplastic resin and other components were blended according to the composition shown in Table 1, and a resin composition was produced using a twin-screw extruder ZSK-40 (manufactured by COPERION WERNER & PFLEIDERER, Germany).
- a twin-screw extruder ZSK-40 manufactured by COPERION WERNER & PFLEIDERER, Germany.
- a first raw material supply port is provided upstream with respect to the flow direction of the raw material
- a first vacuum vent is provided downstream from this
- a second raw material supply port is provided midstream
- a third raw material supply port is downstream thereof.
- a second vacuum vent downstream thereof is downstream thereof.
- each component is added according to the composition and addition method shown in Tables 1 and 2, and the extrusion temperature is 250 to 320 ° C., the screw rotation speed is 300 rpm, and the discharge rate is 100 kg / hour. It was kneaded to produce pellets. Using the obtained resin composition pellets, each of the above evaluations was performed. Evaluation results are shown in Tables 1 and 2.
- the antenna member of the present invention can be suitably used in antenna filters, antenna elements (pendulums), etc., and has industrial applicability.
- it is suitable as an antenna member that can be molded by injection molding and can be applied to all environments such as low temperature, high temperature, and humidity, with little dimensional change and dielectric loss tangent change in high temperature regions while maintaining adhesion to metal films. can be used.
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Abstract
Description
更に、近年の通信の広域化に伴い、アンテナ部材としては、上述の様々な特性を維持しつつ、これらが低温・高温あるいは湿潤環境でも発揮されることが求められるようになってきている。
[1]
熱可塑性樹脂組成物からなる射出成形体を有し、前記射出成形体の少なくとも一部を金属被覆して用いられるアンテナ部材であり、
前記熱可塑性樹脂組成物は、(A-a)ポリフェニレンエーテル系樹脂を含み、
前記熱可塑性樹脂組成物の荷重撓み温度(DTUL)が120℃以上であり、
前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分けて、隣り合う二つの温度域の低温度側を低温度域、高温度側を高温度域としたとき、前記低温度域におけるISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の低温度域膨張率(mm/mm/℃)と、前記高温度域におけるISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の高温度域膨張率(mm/mm/℃)とが、いずれの前記隣り合う二つの温度域においても以下の関係を満たす、アンテナ部材。
-50≦((高温度域膨張率-低温度域膨張率)/低温度域膨張率)×100≦50
[2]
前記熱可塑性樹脂組成物の、28GHzにおける誘電正接の温度依存性が下記の条件を満たす、[1]に記載のアンテナ部材。
1.DTULが120℃以上140℃未満の場合、23℃の時の誘電正接と120℃の誘電正接の値の差が0.004以下
2.DTULが140℃以上の場合、23℃の時の誘電正接と140℃の誘電正接の値の差が0.004以下
[3]
前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分け、各温度域のISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の膨張率の平均値が10×10-5mm/mm/℃以下である、[1]又は[2]に記載のアンテナ部材。
[4]
前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分け、各温度域のISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の膨張率のうち、最大値が10×10-5mm/mm/℃以下である、[3]に記載のアンテナ部材。
[5]
前記熱可塑性樹脂組成物が、(A-b)結晶性樹脂を含む、[1]~[4]のいずれかに記載のアンテナ部材。
[6]
前記熱可塑性樹脂組成物が、(B)無機充填剤を10質量%以上含む、[1]~[5]のいずれかに記載のアンテナ部材。
[7]
前記熱可塑性樹脂組成物が、(A-a)ポリフェニレンエーテル系樹脂を10質量%以上含む、[1]~[6]のいずれかに記載のアンテナ部材。
[8]
屋外用又は屋内用のアンテナ基地局に用いられる、[1]~[7]のいずれかに記載のアンテナ部材。
[9]
クロム酸エッチング無電解銅めっき加工により金属被覆を形成した、[1]~[8]のいずれかに記載のアンテナ部材。
[10]
クロム酸エッチング無電解銅めっき加工により金属被覆を形成したのち、85℃、湿度85%で2000h放置後に、前記金属層に割れが生じない、[1]~[9]のいずれかに記載のアンテナ部材。
[11]
前記熱可塑性樹脂組成物が、(A-c-a)ポリスチレン系樹脂を含む、[1]~[10]のいずれかに記載のアンテナ部材。
[12]
前記熱可塑性樹脂組成物が、(A-c-b)芳香族ビニル単量体単位を主体とするブロックを少なくとも1つと、共役ジエン単量体単位を主体とするブロックを少なくとも1つとを含む、ブロック共重合体、及び/又は該ブロック共重合体の水素添加物を含む、[1]~[11]のいずれかに記載のアンテナ部材。
[13]
アンテナフィルターである、[1]~[12]のいずれかに記載のアンテナ部材。
[14]
アンテナ素子である、[1]~[12]のいずれかに記載のアンテナ部材。
-50≦((高温度域膨張率-低温度域膨張率)/低温度域膨張率)×100≦50
本実施形態における(A)熱可塑性樹脂とは、フィラーや無機充填剤等を除いた樹脂成分のことを指す。かかる樹脂成分としては、例えば、成形用として利用される種々の樹脂、例えば、ポリフェニレンエーテル系樹脂、ポリエステル系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、ビニル系樹脂、オレフィン系樹脂、アクリル系樹脂、芳香族系樹脂等が挙げられる。
本実施形態における(A-a)ポリフェニレンエーテル系樹脂(以下、単に「(A-a)成分」と称する場合がある)の具体的な例としては、例えば、ポリ(2,6-ジメチル-1,4-フェニレンエーテル)、ポリ(2-メチル-6-エチル-1,4-フェニレンエーテル)、ポリ(2-メチル-6-フェニル-1,4-フェニレンエーテル)、ポリ(2,6-ジクロロ-1,4-フェニレンエーテル)等が挙げられ、さらに2,6-ジメチルフェノールと他のフェノール類との共重合体(例えば、特公昭52-17880号公報に記載されてあるような2,3,6-トリメチルフェノールとの共重合体や2-メチル-6-ブチルフェノールとの共重合体)のごときポリフェニレンエーテル共重合体も挙げられる。
上記(A-a)成分は、1種単独で用いてもよいし、2種以上を組み合わせて用いてもよい。
本実施形態には(A-b)結晶性樹脂を含んでもよい。(A-b-a)ポリアミド、(A-b-b)ポリプロピレン、(A-b-c)ポリフェニレンスルフィド樹脂が好適に用いることができる。また、他にもポリエチレン、ポリアセタール、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエーテルエーテルケトン、液晶ポリマー、ポリテトラフルオロエチレン等の結晶性樹脂を用いることができる。
本実施形態の(A-b-a)ポリアミド(以下、単に「(A-b-a)成分」と称する場合がある)は、ポリマー主鎖の繰り返し単位中にアミド結合{-NH-C(=O)-}を有するものであれば、特に制限されない。
本実施形態におけるジカルボン酸単位(a)は、当該単位(a)中、テレフタル酸単位を60~100モル%含有し、好ましくは70~100モル%含有し、より好ましくは80~100モル%含有し、さらに好ましくは90~100モル%含有し、さらにより好ましくは100モル%含有する。当該モル比率がこの範囲にあると、耐熱性に優れた樹脂組成物となる。また、複雑な形状あるいは大型の成形品を成形する際、ハイサイクル成形性に優れる傾向にある。
これらの単位は、1種単独であってもよく、2種以上の組み合わせであってもよい。
本実施形態におけるジアミン単位(b)は、炭素数が9~12の脂肪族ジアミン単位を60~100モル%含有し、好ましくは70~100モル%含有し、より好ましくは80~100モル%含有し、さらに好ましくは90~100モル%含有し、さらにより好ましくは100モル%含有する。炭素数及びジアミン単位のモル比率が上記範囲にあることで、低吸水性と耐熱性のバランスに優れた樹脂組成物となる。
これらの単位は、1種単独であってもよく、2種以上の組み合わせであってもよい。
上記の炭素数が9~12の脂肪族ジアミン単位以外のジアミン単位は、ジカルボン酸単位(ba)中に40モル%以下の範囲で含まれていてもよく、より好ましくは30モル%以下、さらに好ましくは20モル%以下、さらにより好ましくは10モル%以下、最も好ましくは0モル%である。
これらの単位は、1種単独であってもよく、2種以上の組み合わせであってもよい。
これらの単位の(A-b-a)ポリアミド中の合計割合(モル%)は、ポリアミド全体に対して、20モル%以下であることが好ましく、10モル%以下であることがより好ましく、5モル%以下であることがさらに好ましい。
本実施形態の熱可塑性樹脂組成物において、(A)熱可塑性樹脂を100質量%としたときに、成分(A-b-a)の含有量は、25~75質量%であることが好ましく、より好ましくは30~75質量%、さらに好ましくは30~70質量%である。成分(A-b-a)の含有量がこの範囲にあると、機械的強度、低吸水性、寸法精度、及びウェルド強度に優れた樹脂を得ることができる。
(A-b-a)ポリアミドの製造方法としては、特に限定されるものではなく、例えば、以下の種々の方法が挙げられる。
1)ジカルボン酸及びジアミンの水溶液又は水の懸濁液、又はジカルボン酸及びジアミン塩とラクタム及び/又はアミノカルボン酸等の他の成分との混合物(以下、これらを、「その混合物」と略称する場合がある。)の水溶液又は水の懸濁液を加熱し、溶融状態を維持したまま重合させる方法(以下、「熱溶融重合法」ともいう。);
2)ジカルボン酸及びジアミン又はその混合物の水溶液又は水の懸濁液を加熱し、析出したプレポリマーと取り出す方法(「プレポリマー法」);
3)熱溶融重合法で得られたポリアミドを融点以下の温度で固体状態を維持したまま重合度を上昇させる方法(「熱溶融重合・固相重合法」);
4)ジカルボン酸及びジアミン又はその混合物の水溶液又は水の懸濁液を加熱し、析出したプレポリマーをさらにニーダー等の押出機で再び溶融して、その重合度を上昇させる方法(「プレポリマー・押出重合法」);
5)ジカルボン酸及びジアミン又はその混合物の水溶液又は水の懸濁液を加熱し、析出したプレポリマーをさらにポリアミドの融点以下の温度で固体状態を維持して、その重合度を上昇させる方法(「プレポリマー・固相重合法」);
6)ジカルボン酸及びジアミン又はその混合物を、固体状態を維持したまま重合させる方法(「モノマー・固相重合法」);
7)「ジカルボン酸及びジアミンの塩」又はその混合物を、固体状態を維持したまま重合させる方法(「塩・固相重合法」);
8)ジカルボン酸と等価なジカルボン酸ハライド及びジアミンを用いて重合させる方法(「溶液法」)。
本実施形態の熱可塑性樹脂組成物に含まれる(A-b-a)ポリアミドの末端基は、(A-a)ポリフェニレンエーテル系樹脂との反応に関与する。通常、ポリアミド系樹脂は、末端基として、アミノ基やカルボキシル基を有している。一般的に、末端カルボキシル基濃度が高くなると、耐衝撃性が低下し、流動性が向上する傾向にある。また、一般的に、末端アミノ基濃度が高くなると、耐衝撃性が向上し、流動性が低下する傾向にある。但し、本実施形態の熱可塑性樹脂組成物の物性はこれらの傾向に限定されない。
Mn=21900[η]-7900 (Mnは数平均分子量を表す)
分子鎖末端基総数(eq/g)=2/Mn
末端封止率(%)=[(α-β)/α]×100 (1)
(式中、αは分子鎖の末端基の総数(単位=モル;これは、通常、ポリアミド分子の数の2倍に等しい。)を表し、βは封止されずに残ったカルボキシル基末端及びアミノ基末端の合計数(単位=モル)を表す。)
(A-b-b)ポリプロピレン系樹脂としては、特に限定されることなく、例えば、プロピレンを繰り返し単位構造とする単独重合体及び/又は共重合体等が挙げられ、結晶性プロピレン単独重合体、結晶性プロピレン-エチレンブロック共重合体、結晶性プロピレン単独重合体と結晶性プロピレン-エチレンブロック共重合体との混合物が好ましい。
なお、MFRは、ISO1133に準拠し、温度230℃、荷重2.16kgの条件下で測定することができる。MFRは、具体的には、後述の実施例に記載の方法により測定することができる。
本実施形態において、(A-a)成分と(A-b-b)成分との好ましい含有量比率は、(A-a)成分と(A-b-b)成分の総量を100質量部としたときに、(A-a)成分の含有量が10~70質量部、(A-b-b)成分の含有量が30~90質量部である。より好ましくは、(A-a)成分の含有量が10~60質量部であり、(A-b-b)成分の含有量が40~90質量部であり、更に好ましくは、(A-a)成分の含有量が10~50質量部であり、(A-b-b)成分の含有量が50~90質量部の範囲内である。(A-a)成分と(A-b-b)成分との含有比がこの範囲であると、耐衝撃性、耐熱性、引張強度のバランスに優れ好ましい。
本実施形態で用いられる(A-b-c)ポリフェニレンスルフィド樹脂は、その製造方法によりリニア型ポリフェニレンスルフィド樹脂(以下、リニアPPSと略記する場合がある。)および架橋型ポリフェニレンスルフィド樹脂(以下、架橋PPSと略記する場合がある。)に二分される。
前者のリニアPPSは、下記化学式(1)で示されるアリーレンスルフィドの繰返し単位を通常50モル%以上、好ましくは70モル%以上、更に好ましくは90モル%以上を含む重合体である。
[-Ar-S-] ・・・(1)
(ここで、Arはアリーレン基を示し、アリーレン基として、例えばp-フェニレン基、m-フェニレン基、置換フェニレン基(置換基としては炭素数1~10のアルキル基、フェニル基が好ましい。)、p,p’-ジフェニレンスルホン基、p,p’-ビフェニレン基、p,p’-ジフェニレンカルボニル基、ナフチレン基等が挙げられる。)
リニアPPS粉末5gを塩化メチレン80mLに加え、6時間ソックスレー抽出を実施した後、室温まで冷却し、抽出後の塩化メチレン溶液を秤量瓶に移す。更に、上記の抽出に使用した容器を、塩化メチレン合計60mLを用いて、3回に分けて洗浄し、該洗浄液を上記秤量瓶中に回収する。次に、約80℃に加熱して、該秤量瓶中の塩化メチレンを蒸発させて除去し、残渣を秤量し、この残渣量より塩化メチレンによる抽出量、すなわちリニアPPS中に存在するオリゴマー量の割合を求めることができる。
そして、架橋型(半架橋型も含む)ポリフェニレンスルフィド樹脂は、上記したリニアPPSを重合した後に、さらに酸素の存在下でポリフェニレンスルフィド樹脂の融点以下の温度で加熱処理し、酸化架橋を促進してポリマー分子量、粘度を適度に高めたものである。
更にこれらのPPS(リニアPPS、架橋PPS)は酸変性されたPPSでも構わない。ここで酸変性したPPSとは、上記PPSを酸化合物で変性する事によって得られるものであり、該酸化合物としては、アクリル酸、メタクリル酸、マレイン酸、フマル酸、無水マレイン酸等の不飽和カルボン酸又はその無水物や、飽和型の脂肪族カルボン酸や芳香族置換カルボン酸等が挙げられる。さらに、酢酸、塩酸、硫酸、リン酸、ケイ酸、炭酸等の無機化合物系の酸化合物も該酸化合物として挙げることができる。
上記したリニアPPS、架橋PPSのそれぞれの300℃における溶融粘度は、1~10000Pa・s、好ましくは50~8000Pa・s、より好ましくは100~5000Pa・sのものが使用できる。
本実施形態の(A)マトリクス樹脂は、ポリスチレン系樹脂を含んでもよい。ポリスチレン系樹脂としては、アタクチックポリスチレン、ゴム補強されたポリスチレン(ハイインパクトポリスチレン、HIPS)、スチレン含有量が50重量%以上のスチレン-アクリロニトリル共重合体(SAN)、及び該スチレン-アクリロニトリル共重合体がゴム補強されたABS樹脂等が挙げられ、アタクチックポリスチレン及び/又はハイインパクトポリスチレンが好ましい。
本実施形態では、(A-c-b)芳香族ビニル単量体単位を主体とするブロックを少なくとも1つと、共役ジエン単量体単位を主体とするブロックを少なくとも1つとを含む、ブロック共重合体、及び/又は、該ブロック共重合体の水素添加物(以下、単に「(A-c-b)成分」と称する場合がある)をさらに含んでいてもよく、含んでいることが好ましい。本実施形態における(A-c-b)芳香族ビニル単量体単位を主体とするブロックを少なくとも1つと、共役ジエン単量体単位を主体とするブロックを少なくとも1つとを含む、ブロック共重合体、及び/又は、該ブロック共重合体の水素添加物とは、芳香族ビニル単量体単位を主体とする少なくとも1つの芳香族ビニル重合体ブロックと共役ジエン単量体単位を主体とする少なくとも1つの共役ジエン重合体ブロックとを含む非水素化ブロック共重合体及び/又は該ブロック共重合体の水素添加物をいう。
なお、全ビニル結合量は、赤外分光光度計を用いて測定することができる。
なお、測定条件は下記のとおりとしてよい[溶媒:クロロホルム、温度:40℃、カラム:サンプル側(K-G,K-800RL,K-800R)、リファレンス側(K-805L×2本)、流量10mL/分、測定波長:254nm、圧力15~17kg/cm2)]。
また、数平均分子量の測定の際、重合時の触媒失活による低分子量成分が検出されることがあるが、その場合は分子量計算に低分子量成分は含めない。当該低分子量成分は、分子量3000以下の成分を指すものとする。通常、計算された正しい分子量分布(重量平均分子量/数平均分子量)は1.0~1.1の範囲内である。
ここでいう変性されたブロック共重合体とは、分子構造内に少なくとも1個の炭素-炭素二重結合又は三重結合、及び少なくとも1個のカルボン酸基、酸無水物基、アミノ基、水酸基又はグリシジル基を有する、少なくとも1種の変性化合物で変性されたブロック共重合体を指す。
ここでいう「分子構造内に少なくとも1個の炭素-炭素二重結合又は三重結合、及び少なくとも1個のカルボン酸基、酸無水物基、アミノ基、水酸基又はグリシジル基を有する少なくとも1種の変性化合物」としては、変性されたポリフェニレンエーテルで述べた変性化合物と同じものが使用できる。
本実施形態の熱可塑性樹脂組成物には、エチレンとエチレン以外のα-オレフィンとの共重合体(エチレン-αオレフィン共重合体:以下、単に「(A-c-c)成分」と称する場合がある)を含むことができる。
ここで、得られる樹脂組成物の耐薬品性、耐衝撃性の観点から、(A-c-c)成分を構成するモノマー単位として、プロピレン単位は含まれないことが好ましい。なお、「オレフィンからなるオレフィン系重合体」において「プロピレン単位は含まれない」とは、発明の効果を阻害しない程度のプロピレンを構成単位として含む場合も含まれ、例えば、(A-c-c)成分中の(A-c-c)成分を構成する全構成単位中のプロピレン単位の含有量が、0.1質量%未満であることをいう。
(A-c-c)成分は、1種単独で用いてもよいし、2種以上を併用してもよい。また、(c)成分として、2種以上のエチレン-α-オレフィン共重合体を用いてもよい。
なお、上記脆化温度は、ASTM D746に準じて測定することができる。
本実施形態の熱可塑性樹脂組成物には、(A-c-d)スチレン-グリシジルメタクリレート共重合体(以下、単に「(A-c-d)成分」と称する場合がある)を含むことができる。(A-c-d)成分は、(A-a)ポリフェニレンエーテル系樹脂と(A-b-c)ポリフェニレンスルフィド樹脂との混和剤として働く。
本実施形態の熱可塑性樹脂組成物では、上記した成分のほかに、必要に応じて無機充填剤を任意の段階で添加することができる。無機充填剤を入れることで、高温時の寸法変化が抑えられる。
本実施形態において、樹脂組成物の着色方法には特に制限はなく、公知の有機系染顔料、及び無機顔料から選ばれる1種以上の着色剤を使用することができる。
ここでいうDBP吸収量、及び窒素吸着比表面積とは、それぞれASTM D2414、JIS K6217に定められた方法で測定した値をいう。
アジン系染料としては、例えばカラーインデックスにおけるソルベントブラック5(C.I.50415、CAS No.11099-03-9)、ソルベントブラック7(C.I.50415:1、CAS No.8005-20-5/101357-15-7)、アシッドブラック2(C.I.50420、CAS No.8005-03-6/68510-98-5)が挙げられる。
本実施形態の樹脂組成物は、上述の成分以外に、(C)その他の成分として、可塑剤(低分子量ポリオレフィン、ポリエチレングリコール、脂肪酸エステル類等)、帯電防止剤、核剤、流動性改良剤、補強剤、各種過酸化物、展着剤、銅系熱安定剤、ヒンダードフェノール系酸化劣化防止剤に代表される有機系熱安定剤、酸化防止剤、紫外線吸収剤、光安定剤、エチレンビスステアリン酸アミド等の滑剤、無水マレイン酸等の変性材等を含むことができる。
以下、本実施形態の熱可塑性樹脂組成物の特性について述べる。
なお、荷重撓み温度(DTUL)は、後述の実施例に記載の方法で測定される値をいう。
なお、誘電正接は、後述の実施例に記載の方法で測定される値をいう。
1.DTULが120℃以上140℃未満の場合、23℃の時の誘電正接と120℃の誘電正接の値の差が0.004以下
2.DTULが140℃以上の場合、23℃の時の誘電正接と140℃の誘電正接の値の差が0.004以下
上記誘電正接の温度依存性は、熱可塑性樹脂組成物中に低誘電正接且つガラス転移温度が高い熱可塑性樹脂、例えば(A-a)ポリフェニレンエーテル系樹脂を含有させること、等で上記範囲に調整することができる傾向にある。
-50≦((高温度域膨張率-低温度域膨張率)/低温度域膨張率)×100≦50
このことで、射出成型によって成形されたアンテナ部材において、金属被覆が温度変化により剥離しづらくなる傾向にあり、温度変化による部品自体の変形も抑えることができる。
-45≦((高温度域膨張率-低温度域膨張率)/低温度域膨張率)×100≦45
であることがより好ましく、
-40≦((高温度膨張率-低温度域膨張率)/低温度域膨張率)×100≦40
であることがさらに好ましい。
上記関係は、15個に分けた温度域から選択される、隣り合う二つの温度域の全ての組み合わせ(14の組み合わせ)において、満たすものとする。
なお、ISO 11359に記載の方法で測定される上記樹脂組成物のTD方向の膨張率は、後述の実施例に記載の方法で調製した試験片を用いて、後述の実施例に記載の条件で測定される値をいうものとする。
熱可塑性樹脂組成物に、ガラス転移温度が高く、非晶の熱可塑性樹脂であるポリフェニレンエーテルを含有させることにより、隣り合う温度域での膨張率の変動を小さくさせることができ、上記膨張率の関係を調整することができる。
上記平均値は、低膨張率の樹脂を使用すること、及び無機充填剤の種類や配合量等を調整することにより上記範囲内とすることができる。
本実施形態の熱可塑性樹脂組成物は、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとに15個に分けた上記温度域におけるISO 11359に記載の方法で測定されるTD方向の膨張率の最大値が、10×10-5mm/mm/℃以下であることが好ましく、より好ましくは2×10-5mm/mm/℃~8×10-5mm/mm/℃である。上記最大値が10×10-5mm/mm/℃以下であると、温度上昇による大きな寸法変化を抑制でき、より金属被覆の剥離も生じにくくなる。
上記最大値は、低膨張率の樹脂を使用すること、及び無機充填剤の種類や配合量等を調整することにより上記範囲内とすることができる。
本実施形態の樹脂組成物は、(A)成分を構成する各成分、さらに必要に応じて着色剤、無機充填剤、その他の成分を溶融混練することにより製造することができる。
2.本実施形態の樹脂組成物に含まれる(A)成分を構成する各成分の全量及び原料二酸化チタンの一部を溶融混練し(第一混練工程)、第一混練工程で得られた溶融状態の混練物に対し、原料二酸化チタンの残量を供給し、続けて溶融混練を行う(第二混練工程)、製造方法。
3.本実施形態の樹脂組成物に含まれる各成分の全量を溶融混練する方法。
本実施形態の射出成形体は、上述の熱可塑性樹脂組成物よりなる。本実施形態の射出成形体の製造方法は、射出成形によるものである以外、特に限定されない。射出成形においては、射出発泡成形を行い、更に軽量化することもできる。化学発泡・物理発泡共に有効であり、軽量化に貢献することができる。
上記アンテナ部材の少なくとも一部を金属被覆する方法は特に限定されず、従来公知の方法が用いられ得る。乾式めっき又は湿式めっきにより絶縁層上に金属被覆を形成可能である。湿式めっきの場合は、まず、射出成形体の表面を、過マンガン酸塩(過マンガン酸カリウム、過マンガン酸ナトリウム等)、重クロム酸塩、オゾン、過酸化水素/硫酸、硝酸等の酸化剤で粗化処理(エッチング処理)し、凸凹のアンカーを形成する。酸化剤としては、特に過マンガン酸カリウム、過マンガン酸ナトリウム等の水酸化ナトリウム水溶液(アルカリ性過マンガン酸水溶液)が好ましく用いられる。次いで、無電解めっきと電解めっきとを組み合わせた方法で金属被覆を形成する。また金属被覆したいパターンとは逆パターンのめっきレジストを形成し、無電解めっきのみで金属被覆を形成することもできる。その後のパターン形成の方法として、例えば、当業者に公知のサブトラクティブ法、セミアディティブ法などを用いることができる。
本実施形態のアンテナ部材は、金属インクの塗布やめっきをして使用されることがある。
本実施形態のアンテナ部材は、銅害防止性が高く、吸水率が少ない傾向にあるため、上記金属インクの塗布やめっき後の割れを低減することができる。
本実施形態のアンテナ部材は特に高周波領域において、低誘電正接の材料が求められる用途に用いることができる。当該用途では、損失が大きくなると通信機器用部材としての性能が落ちてしまうため、誘電正接のコントロールが重要な技術となる。本実施形態であれば、金属皮膜と密着性を保持しながら高温領域での寸法変化・誘電正接変化が少ない、射出成形により成形されたアンテナ部材を提供可能である。
(A-a-1)2,6-キシレノールを酸化重合して得られたポリフェニレンエーテル樹脂
該ポリフェニレンエーテル樹脂の還元粘度(0.5g/dL、クロロホルム溶液、30℃測定)は、0.52dL/gであった。Tgは約210℃であった。
(A-a-2)2,6-キシレノールを酸化重合して得られたポリフェニレンエーテル樹脂
該ポリフェニレンエーテル樹脂の還元粘度(0.5g/dL、クロロホルム溶液、30℃測定)は、0.40dL/gであった。Tgは約210℃であった。
(A-a-3)2,6-キシレノールを酸化重合して得られたポリフェニレンエーテル樹脂
該ポリフェニレンエーテル樹脂の還元粘度(0.5g/dL、クロロホルム溶液、30℃測定)は、0.32dL/gであった。Tgは約210℃であった。
(A-b-a)ポリアミド
アジピン酸とヘキサメチレンジアミンの等モル塩2400gとアジピン酸100g、及び純水2.5リットルを5リットルのオートクレーブの中に仕込み、良く撹拌した。オートクレーブ内の雰囲気を充分窒素で置換した後、撹拌しながら室温から220℃まで約1時間かけて昇温した。この際、オートクレーブ内のゲージ圧は、水蒸気による自然圧で1.76MPaとなった。続いて、1.76MPa以上の圧にならないよう水を反応系外に除去しながら加熱を続けた。さらに2時間後内温が260℃に到達したら、加熱は続けながら、オートクレーブのバルブの開閉により約40分かけて、内圧が0.2MPaになるまで降圧した。その後、約8時間かけて室温まで冷却した。冷却後オートクレーブを開け、約2kgのポリマーを取りだし、粉砕した。
得られたポリアミドはMw=38700、Mw/Mn=2.1であった。なお、Mw、Mnは、GPC(移動層:ヘキサフルオロイソプロパノール、標準物質:PMMA(ポリメチルメタクリレート))を用いて求めた。
また、特開平7-228689号公報の実施例に記載されている末端アミノ基濃度の測定方法に従い測定した結果、末端アミノ基濃度は38μmol/gであった。Tgは約50℃であった。
テレフタル酸9743.5g(58.65モル)、1,9-ノナンジアミン8027.8g(51.0モル)、2-メチル-1,8-オクタンジアミン1424.6g(9.0モル)、安息香酸329.7g(2.7モル)、次亜リン酸ナトリウム一水和物19.6g(原料に対して0.1質量%)及び蒸留水5Lを40Lオートクレーブに入れ、窒素置換した。
100℃で30分間撹拌し、2時間かけて内部温度を210℃に昇温した。この時、オートクレーブは22kg/cm2まで昇圧した。そのまま1時間反応を続けた後230℃に昇温し、その後2時間、230℃に温度を保ち、水蒸気を徐々に抜いて圧力を22kg/cm2に保ちながら反応させた。次に、30分かけて圧力を10kg/cm2まで下げ、更に1時間反応させて、極限粘度[η]が0.25dl/gのプレポリマーを得た。これを、100℃、減圧下で12時間乾燥し、2mm以下の大きさまで粉砕した。これを230℃、0.1mmHg下にて、10時間固相重合し、融点が306℃、極限粘度[η]が0.80dl/gであった。また、特開平7-228689号の実施例に記載されているアミノ基末端濃度の測定方法に従い測定した結果、末端アミノ基濃度は20μmol/gであった。Tgは約125℃であった。
(A-b-b-1)ポリプロピレン MFR=2g/10分のポリプロピレン単独重合体
なお、MFRは、ISO1133に準拠し、温度230℃、荷重2.16kgの条件下で測定した。Tgは約0℃であった。
(A-b-b-2)無水マレイン酸で変性された数平均分子量(Mn):60,000、重量平均分子量(Mw):91,000のポリプロピレン。Tgは約0℃であった。
(A-b-c-1):溶融粘度(フローテスターを用いて、300℃、荷重196N、L/D=10/1で6分間保持した後測定した値。)が30Pa・s、塩化メチレンによる抽出量が0.7質量%、-SX基量が32μmol/gのp-フェニレンスルフィドの繰り返し単位を有するリニア型のPPS。Tgは約80℃であった。
(A-b-c-2):溶融粘度(フローテスターを用いて、300℃、荷重196N、L/D=10/1で6分間保持した後測定した値。)が60Pa・s、320℃の溶融状態で捕集される揮発分160質量ppmの架橋型のPPS。Tgは約80℃であった。
(A-c-a-1)ハイインパクトポリスチレン(PSジャパン株式会社製H9405)Tgは約100℃であった。
(A-c-a-2)ハイインパクトポリスチレン(ペトロケミカルズ(株)製、商品名「CT-60」)Tgは約100℃であった。
(A-c-a-3)ポリスチレン(PSジャパン株式会社製GPPS 680)Tgは約100℃であった。
(A-c-b-1)水添ブロック共重合体(旭化成株式会社製タフテック(商標)H1051)
(A-c-b-2)水添ブロック共重合体(旭化成株式会社製 タフテック(商標)H1081)
(A-c-b-3)
公知の方法により、重合体ブロックIをポリスチレンからなるものとし、重合体ブロックIIをポリブタジエンからなるものとして、II-I-II-Iのブロック構造を有するブロック共重合体を合成した。公知の方法により、合成したブロック共重合体に水素添加を行った。重合体の変性は行わなかった。得られた未変性水素添加ブロック共重合体の物性を下記に示す。
水素添加後のブロック共重合体におけるポリスチレンの含有量:44質量%、水素添加後のブロック共重合体の数平均分子量(Mn):95300、重量平均分子量(Mw):113600、水素添加後のポリブタジエンブロックにおける1,2-ビニル結合量(全ビニル結合量):79%、ポリブタジエンブロックを構成するポリブタジエン部分に対する水素添加率:99%
(A-c-b-4)
スチレン-エチレン-プロピレン-スチレンブロック共重合体エラストマー(クラレ株式会社製、セプトン 2023)
(A-c-c-1)エチレン?α?オレフィン共重合体(三井化学株式会社製 タフマー P-0680J)
(A-c-d-1)グリシジルメタクリレートを5質量%含有するスチレン-グリシジルメタクリレート共重合体(重量平均分子量:110,000)
(A-c-e)熱可塑性ノルボルネン樹脂
(A-c-e-1)熱可塑性ノルボルネン系樹脂 (日本ゼオン株式会社製、ZEONEX480)Tgは約140℃であった。
(B-1)ガラス繊維(日本電気硝子社製 ECS03-T249)
(B-2)ガラス繊維(日本電気硝子社製 ECS03-T747)
(B-3)ガラス繊維(日本電気硝子社製 ECS03-T497)
(B-4)タルク(竹原化学工業製 ハイトロンA)
(B-5)タルク(林化成工業製 タルカンパウダー PK-C)
(B-6)ガラスフレーク(日本板硝子製 「フレカ REFG-301」)
(B-7)ガラスフレーク(日本板硝子製 MEG160FY M06)
(C-1)エチレンビスステアリン酸アミド(花王社製「カオーワックスEB-G」)
(C-2)無水マレイン酸(日本油脂(株)製、「クリスタルMAN」)
(C-3)過酸化物(日本油脂株式会社製、「パーヘキサ25B-40」)
実施例及び比較例で行った各評価試験は、以下のようにして行った。
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間15秒の条件で60mm×60mm×2.0mmの平板を作製した。また、平板を切削し、下記条件で測定した。
測定装置:vector network analyzer HP8510C(アジレント・テクノロジー)
synthesized sweeper HP83651A(同上)
test set HP8517B(同上)
試験片寸法:40mm×4mm×2.0mm
共振器の形状:内径229mm、高さ40mmの円筒
測定方向:1方向
測定周波数:1GHz付近(TM010モード)
前処理:90h/22±1℃/60±5%RH
試験環境:22℃/56%RH
誘電正接は低ければ低いほど性能が良いと判断した。
(1-3)、(1-4)28GHzの誘電率・誘電正接
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間20秒の条件で150mm×150mm×4.0mmの平板を作製し、下記条件で28GHzの誘電率を測定した。
測定周波数:22GHz-33GHz
測定方法:周波数変化法
測定装置:ベクトルネットワークアナライザ(KeysightPNA N5247B10MHz-67GHz)、キーコム社高周波用フリースペースタイプSパラメータ測定治具、制御PC
測定環境条件:室温26℃、湿度50%
(1-5)吸水後の誘電正接
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間20秒の条件で60mm×60mm×0.9mmの平板を作製し、80℃の温水に144時間浸漬した後、下記条件で10GHzの誘電正接を測定した。
測定周波数:10GHz
測定装置:10MHz to 43.5GHz PNA network analyzer N5224B、10GHz Split Post Dielectric Resonator N1501AE10
測定環境条件:室温23℃、湿度50%
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間15秒、ISOダンベル成形条件に準拠した条件及び金型で評価用ISOダンベルを作製した。また、該ISOダンベルを切削し、荷重撓み温度(DTUL)測定用テストピースを作製した。上記荷重撓み温度測定用テストピースを用いて、荷重撓み温度:DTUL(ISO 75:1.80MPa荷重)の測定を行った。
値が大きいほど、耐熱性に優れていると判定した。
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間15秒の条件で90mm×50mm×2.5mmの平板を作製した。また、該平板に対し、クロム酸でエッチングした後に、無電解銅めっきを施した。この時、平板全面にめっきが乗った場合に〇、めっきが乗らなかった場合に×と表記し、めっきが乗るものほど通信機器用部品として優れていると判断した。
更には、めっきに対し、-30℃~85℃の間でヒートサイクル試験を各60分、30サイクル行った後に、カッターで×印に切り込みを入れてから、セロハン(登録商標)テープを貼り付け、剥離試験を実施した。この時、目視でめっきが剥がれなかった場合に〇、目視でめっきが剥がれた場合に×と表記し、剥がれなかったものほど通信機器用部品として優れていると判断した。めっきが剥がれたかどうかの判断は、セロハン(登録商標)テープを貼り付け、剥がした部分の面積(100%)において10%以上の面積で樹脂の表面が見えたかどうかで判断した。
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力250MPa、射出時間20秒、冷却時間15秒の条件で60mm×60mm×0.9mmの平板を作製した。該平板を、切削し、37mm×37mm×0.9mmにして、下記装置を用いて誘電正接を測定した。この時、DTULが120℃以上140℃以下の材料の場合、23℃の時の誘電正接と120℃の誘電正接の値を比べた。DTULが140℃以上の材料の場合、23℃の時の誘電正接と140℃の誘電正接の値を比べた。これらの差が小さいほど通信機器用部品として優れていると判断した。
測定装置:キーサイト・テクノロジー製N5227B PNA マイクロ波ネットワーク・アナライザ67GHz
共振器;FATEC製平衡形円板共振器
恒温槽:エスペック製SU-662
得られた樹脂組成物のペレットを、シリンダー温度250~350℃に設定した小型射出成形機(商品名:EC75-SXII、東芝機械社製)に供給し、金型温度70~130℃、射出圧力200MPa、射出時間20秒、冷却時間15秒、ISOダンベル成形条件に準拠した条件及び金型で評価用ISOダンベルを作製した。また、該ISOダンベルから図1に示すように試験片を切り出し、温度23℃、湿度50%RHに調節された実験室内に168時間静置後、ISO11359に記載の方法にて、熱機械分析装置(TMA、商品名TMA/SS6100、SIIテクノロジー社製)を用いて、以下の条件で膨張率を測定した。
そして、15個の温度域の膨張率のうち、最も高い値を膨張率の最大値(mm/mm/℃)とし、また、15個の温度域の膨張率の平均値を平均膨張率として(平均膨張率)(mm/mm/℃)算出した。
また、15個の温度域のうち、任意の隣り合う二つの温度域の低温度側を低温度域、高温度側を高温度域としたとき、上記低温度域の膨張率(低温度域膨張率(mm/mm/℃))と上記高温度域の膨張率(高温度域膨張率(mm/mm/℃))とから、以下の式を用いて、低温度域と高温度域との膨張率の変化割合を求め、最も変化割合が大きかった値を、変化割合の最大値(%)とした。
(低温度域と高温度域との膨張率の変化割合)=(高温度域膨張率-低温度域膨張率/低温度域膨張率)×100
上記隣り合う任意の2個の温度域とは、温度-30℃から120℃までを10℃ごとの15個に分けた温度域(-30℃から-20℃、-20℃から-10℃、-10℃から0℃、・・・、110℃から120℃)のうち、隣り合う温度域の14種の組み合わせ(例えば、-30℃から-20℃の低温度域と-20℃から-10℃の高温度域との組み合わせ、-20℃から-10℃の低温度域と-10℃から0℃の高温度域との組み合わせ等)をいう。
下記条件にてアンテナ効率のシミュレーションを行った。
アンテナ基材:60× 7 × 1mm3 、全面べたGND、パターン幅1mm、厚さ25μm。
銅+Niメッキ
メイン基板:60× 130 × 1mm3 ,比誘電率 4.0 誘電損失 0.020
厚さ35 μ m 導電率 5.8 × 107 S/m
シミュレーション装置:CST 社の MW STUDIO
動作周波数帯で反射係数が6dB 以下となるよう調整した。
材料の誘電特性(誘電率と誘電正接)
材料の誘電特性は(4)の方法で測定した。
<高温域>
材料のDTULの値に応じて以下の値を用いた。
DTULが120℃以下の材料の場合、100℃の時の誘電特性
DTULが120℃以上140℃以下の材料の場合、120℃の時の誘電特性
DTULが140℃以上の材料の場合、140℃の誘電特性
<低温域>
―30℃の時の誘電特性を用いた。
そして、シミュレーションから4GHzのトータル効率を得て、トータル効率をアンテナ効率とした。トータル効率は0に近いほど好ましく、アンテナとしての性能が高いと言える。
(A)熱可塑性樹脂、及びその他の成分を表1に示した組成で配合し、二軸押出機ZSK-40(COPERION WERNER&PFLEIDERER社製、ドイツ国)を用いて樹脂組成物の製造を行った。この二軸押出機において、原料の流れ方向に対して上流側に第1原料供給口を設け、これより下流に第1真空ベント、中流に第2原料供給口、その下流に第3原料供給口、さらにその下流に第2真空ベントを設けた。
上記のように設定した押出機を用い、表1及び2に示す組成及び添加方法で各成分を添加し、押出温度250~320℃、スクリュー回転数300rpm、吐出量100kg/時間の条件にて溶融混練し、ペレットを製造した。
得られた樹脂組成物ペレットを用いて、上述の各評価を行った。評価結果を表1および2に示す。
Claims (14)
- 熱可塑性樹脂組成物からなる射出成形体を有し、前記射出成形体の少なくとも一部を金属被覆して用いられるアンテナ部材であり、
前記熱可塑性樹脂組成物は、(A)熱可塑性樹脂を含み、前記(A)熱可塑性樹脂は、(A-a)ポリフェニレンエーテル系樹脂を含み、
前記熱可塑性樹脂組成物の荷重撓み温度(DTUL)が120℃以上であり、
前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分けて、隣り合う二つの温度域の低温度側を低温度域、高温度側を高温度域としたとき、前記低温度域におけるISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の低温度域膨張率(mm/mm/℃)と、前記高温度域におけるISO 11359に記載の方法で測定される、前記樹脂組成物のTD方向の高温度域膨張率(mm/mm/℃)が、いずれの前記隣り合う二つの温度域においても以下の関係を満たす、アンテナ部材。
-50≦((高温度域線膨張率-低温度域線膨張率)/低温度域線膨張率)×100≦50 - 前記熱可塑性樹脂組成物の、28GHzにおける誘電正接の温度依存性が下記の条件を満たす、請求項1に記載のアンテナ部材。
1.DTULが120℃以上140℃未満の場合、23℃の時の誘電正接と120℃の誘電正接の値の差が0.004以下
2.DTULが140℃以上の場合、23℃の時の誘電正接と140℃の誘電正接の値の差が0.004以下 - 前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分け、各温度域のISO 11359に準拠して測定される、前記樹脂組成物のTD方向の線膨張率の平均値が10×10-5mm/mm/℃以下である、請求項1又は2に記載のアンテナ部材。
- 前記熱可塑性樹脂組成物の、-30℃から120℃まで温度を上昇させる際の温度を10℃ごとの温度域に分け、各温度域のISO 11359に準拠して測定される、前記樹脂組成物のTD方向の線膨張率のうち、最大値が10×10-5mm/mm/℃以下である、請求項3に記載のアンテナ部材。
- 前記(A)熱可塑性樹脂が、(A-b)結晶性樹脂を含む、請求項1又は2に記載のアンテナ部材。
- 前記熱可塑性樹脂組成物が、(B)無機充填剤を10質量%以上含む、請求項1又は2に記載のアンテナ部材。
- 前記(A)熱可塑性樹脂が、(A-a)ポリフェニレンエーテル系樹脂を10質量%以上含む、請求項1又は2に記載のアンテナ部材。
- 屋外用又は屋内用のアンテナ基地局に用いられる、請求項1又は2に記載のアンテナ部材。
- クロム酸エッチング無電解銅めっき加工により金属被覆を形成した、請求項1又は2に記載のアンテナ部材。
- クロム酸エッチング無電解銅めっき加工により金属被覆を形成したのち、85℃、湿度85%で2000h放置後に、前記金属層に割れが生じない、請求項1又は2に記載のアンテナ部材。
- 前記熱可塑性樹脂組成物が、(A-c-a)ポリスチレン系樹脂を含む、請求項1又は2に記載のアンテナ部材。
- 前記熱可塑性樹脂組成物が、(A-c-b)芳香族ビニル単量体単位を主体とするブロックを少なくとも1つと、共役ジエン単量体単位を主体とするブロックを少なくとも1つとを含む、ブロック共重合体、及び/又は、該ブロック共重合体の水素添加物を含む、請求項1又は2に記載のアンテナ部材。
- アンテナフィルターである、請求項1又は2に記載のアンテナ部材。
- アンテナ素子である、請求項1又は2に記載のアンテナ部材。
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