Electromagnetic wave-shielding thermoplastic resin composition

This invention relates to an electromagnetic wave-shielding thermoplastic resin composition having a high effect of shielding electromagnetic waves.
With the recent advance in electronic devices, a problem has arisen in relation to an electromagnetic environment around these electronic devices. This is presumably because the number of devices equipped with a microcomputer or the like has increased because of the advance in the large-scale integrated circuit technology, and casings of the electronic devices have been made of plastics because of their mass-producibility, economy and light weight so that the electromagnetic environment in which the electronic devices are placed has diversified. These electronic devices (computers, office machines, household electrical appliances, etc.) have reduced signal levels as a result of high integration, and are accordingly susceptible to the influences of noises.
On the other hand, elements or electronic circuits within these devices have an oscillating function, and issue noises outside and cause electromagnetic disorders. To solve this problem, it may be possible to improve the electronic circuits such that they are free from the effects of noises. In any case, it is necessary to impart an electromagnetic wave-shielding effect to casings that surround these electronic devices.
There are roughly two methods of imparting the electromagnetic wave shielding function to synthetic resins from which the casings are made, one involving coating an electrically conductive film on the surface of fabricated plastic casings by plating, painting, flame-spraying, foil bonding, etc., and the other involving making a composite material by incorporating an electrically conductive filler material into a plastic material.
According to the former method, the conductive film is likely to be exfoliated and drop off by the impact of falling, changes with time, thermal shocks, etc. This naturally results in a reduction in the electromagnetic wave-shielding effect. Moreover, the exfoliated fragments of the conductive film fall onto the electronic circuits, and might cause an accident such as damage to the devices, electric shock or fire.
According to the latter method, graphite, carbon black, carbon fibers, silver powder, copper powder, nickel powder, stainless steel powder, stainless steel fibers, aluminum flakes, aluminum ribbons, aluminum fibers, brass fibers, aluminum-coated glass fibers and nickel-coated glass fibers have been studied as the electrically conductive filler. If such an electrically conductive filler is increased to an extent of obtaining a sufficient electromagnetic wave-shielding effect, the mechanical strength of the resulting plastic article is frequently reduced. Also, it is not easy to mix it uniformly with a synthetic resin to impart a sufficient electromagnetic wave-shielding effect.
Fibers of stainless steel, brass or copper which will become effective in small amounts of mixing have mainly been studied recently. However, a resin composition comprising such metallic fibers has the defect that there are variations in resistance in molded articles prepared from the composition because of the orientation of the fibers that occurs during the molding, and moreover, the moldability of such a composition is poor.
It is an object of this invention to provide an electromagnetic wave-shielding thermoplastic resin composition having a novel composition and a high electromagnetic wave-shielding effect.
Another object of this invention is to provide a thermoplasic resin composition having a high electromagnetic wave-shielding effect over a broad frequency region.
Still another object of this invention is to provide a thermoplastic resin composition having a high electromagnetic wave-shielding effect and excellent mechanical strength.
Yet another object of this invention is to provide an electromagnetic wave-shielding thermoplastic resin composition which can be molded without difficulty.
Further objects and advantages of this invention will become apparent from the following description.
According to this invention, the above objects and advantages of this invention are achieved by an electromagnetic wave-shielding thermoplastic resin composition comprising
(A) 100 parts by weight of a thermoplastic resin selected from the group consisting of polypropylene resins, polystyrene resins, acrylonitrile/styrene/butadiene copolymer resin, polybutylene terephthalate resins, polyphenylene ether resins and linear aliphatic polyamide resins,
(B) 30 to 300 parts by weight of electrically conductive glass fibers,
(C) 5 to 40 parts by weight of carbon black, and
(D) 5 to 40 parts by weight of graphite.
The electromagnetic wave-shielding thermoplastic resin composition of this invention contains the specific thermoplastic resin (A).
The polypropylene resins may include a homopolymer of propylene and copolymers of propylene with other alpha-olefins. The copolymers include random copolymers and block copolymers.
Preferred propylene copolymers are composed of at least 90 mole % of propylene units and not more than 10 mole % of units of another alpha-olefin. Preferred examples of the other alpha-olefins are alpha-olefins having 2 to 8 carbon atoms such as ethylene, butene-1, pentene-1, 3-methylpentene-1 and 4-methylpentene-1. These alpha-olefins may be used in combination.
The polystyrene resins may include a homopolymer of styrene and random copolymers of styrene and other copolymerizable monomers. Examples of the other copolymerizable monomers are styrene-type monomers such as alpha-methylstyrene and chlorostyrene. The proportion of units derived from such other copolymerizable monomers is preferably 5 to 10 mole % in the copolymers.
Further examples of the polystyrene resins include impact-resistant polystyrenes obtained by graft-polymerizing styrene-type monomers such as styrene, alpha-methylstyrene and chlorostyrene with diene-type rubber elastomers such as polybutadiene.
The above polystyrene resins may be used singly or in combination.
A resin generally called ABS resin composed of, for example, 25 to 30% by weight of acrylonitrile units, 25 to 30% by weight of butadiene units and the balance (the total being 100% by weight) being styrene units is preferably used as the acrylonitrile/styrene/butadiene copolymer resin.
The polybutylene terephthalate resins include polybutylene terephthalate and copolymers preferably composed of at least 60 mole % of butylene terephthalate units and not more than 40 mole % of comonomer units. The comonomer units are derived from an aliphatic, alicyclic or aromatic diol component such as ethylene glycol, propylene glycol, decamethylene glycol, neopentyl glycol, gamma-xylylene glycol, cyclohexanediol or cyclohexane dimethanol and an aromatic, alicyclic or aliphatic dicarboxylic acid component such as isophthalic acid, phthalic acid, terephthalic acid, p-hydroxybenzoic acid, m-hydroxybenzoic acid, naphthalenedicarboxylic acid, oxalic acid, adipic acid, sebacic acid or cyclohexanedicarboxylic acid.
The polyphenylene ether resins include a homo- or co-polymer of phenylene ether, and a grafted poly-phenylene ether polymer obtained by grafting an aromatic vinyl compound to such a homo- or co-polymer.
Preferably, the homopolymer or copolymer of polyphenylene ether is obtained by polycondensing a monocyclic phenol represented by the following formula ##STR1## wherein R.sup.1 represents a lower alkyl group having 1 to 3 carbon atoms, and R.sup.2 and R.sup.3, independently from each other, represent a hydrogen atom or an alkyl group having 1 to 3 carbon atoms.
The homopolymer can be obtained from a single monocyclic phenol, and the copolymer, from two or more monocyclic phenols.
The alkyl group having 1 to 3 carbon atoms in general formula (I) denotes methyl, ethyl, n-propyl and iso-propyl groups.
Examples of the monocyclic phenol of general formula (I) include 2,6-dimethylphenol, 2,6-diethylphenol, 2,6-dipropylphenol, 2-methyl-6-ethylphenol, 2-methyl-6-propylphenol, 2-ethyl-6-propylphenol, o-cresol, 2,3-dimethylphenol, 2,3-diethylphenol, 2,3-dipropylphenol, 2-methyl-3-ethylphenol, 2-methyl-3-propylphenol, 2-ethyl-3-methylphenol, 2-ethyl-3-propylphenol, 2-propyl-3-methyl-phenol, 2-propyl-3-ethylphenol, 2,3,6-trimethylphenol, 2,3,6-triethylphenol, 2,3,6-tripropylphenol, 2,6-dimethyl-3-ethylphenol and 2,6-dimethyl-3-propylphenol. Accordingly, examples of polyphenylene ether resins obtained by polycondensing these monocyclic phenols include homopolymers such as poly(2,6-dimethyl-1,4-phenylene)ether, poly(2,6-diethyl-1,4-phenylene)ether, poly(2,6-dipropyl-1,4-phenylene)ether, poly(2-methyl-6-ethyl-1,4phenylene)ether, poly(2-methyl-6-propyl-1,4-phenylene) ether and poly(2-ethyl-6-propyl-1,4-phenylene)ether, and copolymers such as 2,6-dimethylphenol/2,3,6-trimethylphenol copolymer, 2,6-dimethylphenol/2,3,6-triethylphenol copolymer, 2,6-diethylphenol/2,3,6-trimethylphenol copolymer and 2,6-dipropylphenol/2,3,6-trimethylphenol copolymer.
Of these, poly(2,6-dimethyl-1,4-phenylene)ether and 2,6-dimethylphenol/2,3,6-trimethylphenol copolymer are preferred.
Preferred as the aforesaid grafted polymer is a graft polymer obtained by grafting an aromatic vinyl compound represented by the following formula (II) ##STR2##
wherein R.sup.4 represents a hydrogen atom or a lower alkyl group, Z represents a halogen atom or a lower alkyl group, and p is 0 or an integer of 1 to 3,
to the polyphenylene ether homo- or co-polymer. The grafted polymer can be produced, for example, by the method described in Japanese Laid-Open Patent Publication No. 126,800/1975. Examples of the aromatic vinyl compound are styrene, alpha-methylstyrene, vinyltoluene, vinylxylene, ethyl styrene, n-propylstyrene, isopropylstyrene, chlorostyrene and bromostyrene.
Especially preferred grafted polymers are a graft polymer obtained by grafting styrene to poly(2,6-dimethyl-1,4-phenylene)ether and a graft polymer obtained by grafting styrene to 2,6-dimethylphenol/2,3,6-trimethylphenol copolymer.
The polyphenylene ether resins used in this invention may be a mixture of at least two of the above homopolymers and copolymers.
The linear aliphatic polyamide resins are polyamides from diamines and dicarboxylic acids one or both of which are aliphatic, and polyamides from aminocarboxylic acids or aliphatic lactams. Preferred diamines are those having 6 to 12 carbon atoms, and examples include hexamethylenediamine, decamethylenediamine, dodecamethylenediamine, 2,2,4-trimethylhexamethylenediamine, 1,4-bis(aminomethyl)cyclohexane, p-xylylenediamine and m-xylylenediamine.
The dicarboxylic acids are preferably those having 6 to 12 carbon atoms Examples include aliphatic, alicyclic and aromatic dicarboxylic acids such as adipic acid, sebacic acid, cyclohexanedicarboxylic acid, terephthalic acid and isophthalic acid.
Lactams which give polyamides by ring-opening polymerization are preferably those having 6 to 12 carbon atoms, and examples include epsilon-caprolactam and omega-dodecalactam. The aminocarboxylic acids are preferably those having 6 to 12 carbon atoms, such as 6-aminocarboxylic acid, 11-aminoundecanoic acid and 12-aminododecanoic acid.
66-nylon, 6-nylon and 6,10-nylon are especially preferably used as the aliphatic polyamides.
The aliphatic polyamide resins may be used singly or as a mixture of two or more.
At least one of the above-mentioned various resins may be used as the thermoplastic resin (A) in this invention. For example, a combination of the polyphenylene ether resin and the polystyrene resin is preferred as the resin mixture.
The thermoplastic resin (A) used in this invention has a melt index of preferably 5 to 50 g/10 min. and more preferably 20 to 50 g/10 min.
The component (B) of the composition of this invention consists of electrically conductive glass fibers. The conductive glass fibers are, for example, glass fibers to which an electrically conductive coating such as a metallic coating is applied. The conductive glass fibers are produced, for example, by applying a film of a metal such as copper, aluminum or nickel or a metal alloy to the glass fibers by, for example, electroless plating or vapor deposition.
The proportion of the conductive glass fibers (B) is 30 to 300 parts by weight per 100 parts by weight of the thermoplastic resin (A). If the proportion exceeds the specified upper limit, the ease of extruding the resulting composition is reduced, and if it is below the lower limit, no sufficient electromagnetic wave-shielding function can be obtained. The preferred proportion of the conductive glass fibers (B) is 100 to 200 parts by weight on the same basis.
The component (C) of the composition of this invention is carbon black. Examples of the carbon black are thermal black, channel black, acetylene black, Ketjen black and furnace black, and furnace black is especially preferred.
The proportion of the carbon black (C) is 5 to 40 parts by weight per 100 parts by weight of the thermoplastic resin (A). If the proportion exceeds the specified upper limit, the ease of extruding the resulting composition is reduced, and if it is below the lower limit, no sufficient electromagnetic wave-shielding function can be obtained. The preferred proportion of the carbon black (C) is 15 to 25 parts by weight on the same basis.
The component (D) constituting the composition of this invention is graphite. The graphite may be of natural or artificial origin and may be scale-like or lumpy. Natural scale-like graphite is preferred.
The proportion of the graphite (D) is 5 to 40 parts by weight per 100 parts by weight of the thermoplastic resin (A). If it exceeds the upper limit, the ease of extruding the resulting composition is reduced, and if it is below the lower limit, no sufficient electromagnetic wave shielding function can be obtained. The preferred proportion of the graphite (D) is 15 to 25 parts by weight on the same basis.
In addition to the components (A), (B), (C) and (D), the composition of this invention may contain at least one of stabilizers against deterioration by oxidation, heat, ultraviolet light, etc., agents for preventing such deterioration, a nucleating agent, a plasticizer, a fire retardant, an antistatic agent, a lubricant, etc.
The components constituting the composition of this invention may be mixed by various methods. For example, they may be melt-kneaded at a temperature 5.degree. to 50.degree. C. higher than the melting point or softening point of the thermoplastic resin using an ordinary vent-type extruder or a similar device. Investigations of the present inventors have shown that the composition comprising the components (A) to (D) exhibits a high electromagnetic wave-shielding effect over a broad frequency band region, for example from 10 MHz to 300 MHz, and has excellent mechanical strength.
The present inventors furthered their investigations, and have found that when a combination of a polyamide resin derived from xylylenediamine and 66-nylon is used as the thermoplastic resin, it is possible to impart the same properties as above especially advantageously.
Such an electromagnetic wave-shielding thermoplastic resin composition of this invention comprises
(A) 100 parts by weight of a polyamide resin derived from xylylenediamine as a main diamine component and an alpha,omega-linear aliphatic dicarboxylic acid as a main dicarboxylic acid component,
(A') 5 to 100 parts by weight of nylon 66,
(B) 30 to 300 parts by weight of conductive glass fibers,
(C) 5 to 40 parts by weight of carbon black, and
(D) 5 to 40 parts by weight of graphite.
Examples of the polyamide resin (A) include polyamide resins (i.e., MX-nylon) produced by the polycondensation reaction of xylylenediamine composed mainly of m-xylylenediamine such as m-xylylenediamine itself or a mixture of 60% or more of m-xylylenediamine and 40% or less of p-xylylenediamine with an alpha,omega-linear aliphatic dicarboxylic acid having 6 to 12 carbon atoms. Specific examples of the dicarboxylic acid are adipic acid, sebacic acid, suberic acid, undecanedioic acid and dodecanedioic acid. Adipic acid is most suitable. The MX-nylons can have a relative viscosity, measured at 25.degree. C. for a solution of lg of the polymer in 100 ml of 98% sulfuric acid, of generally 1.7 to 2.9, preferably 1.9 to 2.4.
The preferred proportions of the components (A'), (B), (C) and (D) in the above composition are as follows:
______________________________________(A') nylon 66 10 to 20 parts by weight(B) conductive 100 to 200 parts by weight glass fibers(C) carbon black 15 to 25 parts by weight(D) graphite 15 to 25 parts by weight______________________________________
The nylon 66, conductive glass fibers, carbon black and graphite may be the same as those described hereinabove.
The following examples illustrate the present invention more specifically.
In these examples, all parts are by weight, and the various properties were measured by the following methods.
(1) Tensile strength: ASTM D638
(2) Tensile elongation: ASTM D638
(3) Tensile modulus: ASTM D638
(4) Flexural strength: ASTM D790
(5) Flexural modulus: ASTM D790
(6) Izod impact strength: ASTM D256
(7) Heat distortion temperature: ASTM D648
(8) Volume inherent resistivity: ASTM D257
(9) Electromagnetic shielding property: ADVANTEST method

EXAMPLE 1
One hundred parts of nylon 66, 106 parts of nickel-copper-nickel three layer-coated glass fibers having a fiber length of 3 to 6 mm and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm (EMITEC, made by Asahi Fiber Glass Co., Ltd.), 15 parts of natural scale-like graphite powder (Special CP; Japan Graphite Co., Ltd.) and 15 parts of highly electrically conducture furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 270.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a polyamide resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 275.degree. C.
Die temperature: 75.degree. C.
Injection and pressure maintenance time: 5 seconds
Cooling time: 20 seconds
Injection pressure: 500 to 600 kg/cm.sup.2
The results are shown in Table 1.
EXAMPLES 2-6
Example 1 was repeated except that the types or the proportions of the components were changed as indicated in Table 1 (in Examples 4 to 6, the resin temperature at the time of injection molding was changed to 240.degree. C).
The results are shown in Table 1.
TABLE 1__________________________________________________________________________Example 1 2 3 4 5 6__________________________________________________________________________Propor- Nylon 66 100 100 100 -- -- --tions Nylon 6 -- -- -- 100 100 100(parts Carbon black 15 5 20 15 5 20by Graphite 15 5 20 15 5 20weight) Conductive glass 106 30 150 106 30 150 fiberMechan- Tensile strength 1030 963 1150 980 915 1090ical kg/cm.sup.2pro- Tensile elongation % 1.10 0.94 1.41 1.75 3.30 2.30perties Tensile modulus 133 122 132 117 107 119 10.sup.3 kg/cm.sup.2 Flexural strength 1660 1390 1600 1680 1410 1580 kg/cm.sup.2 Flexural modulus 107 81 127 106 81 116 10.sup.3 kg/cm.sup.2 Izod impact strength 5.1 3.8 4.3 5.5 3.1 4.0 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 50.2 16.2 30.0 60.0 18.5 20.5 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 250 250 250 205 205 208 temperature .degree.C.Elec- Volume inherent 2.4 45 0.83 3.6 21 0.39trical resistivity .OMEGA. .multidot. cmpro- Electromagneticperties shielding property (electric field 30 MHz) db 48 -- -- 50 -- -- (electric field 300 MHz) db 67 -- -- 69 -- -- (magnetic field 30 MHz) db 28 -- -- 32 -- -- (magnetic field 300 MHz) db 69 -- -- 70 -- --__________________________________________________________________________
EXAMPLE 7
One hundred parts of poly(m-xylene adipamide) having an average molecular weight of 16,000 (abbreviated as "nylon MXD6" hereinafter), 13 parts of nylon 66, 120 parts of nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 mm and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 17 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 17 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 270.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a polyamide resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 260.degree. C.
Die temperature: 130.degree. C.
Injection and pressure maintenance time: 5 seconds
Cooling time: 20 seconds
Injection pressure: 500 to 600 kg/cm.sup.2
The results are shown in Table 2.
EXAMPLES 8-10
Example 7 was repeated except that the types or the proportions of the components were changed as indicated in Table 2.
The results are shown in Table 2.
In Example 10, brominated polystyrene and antimony trioxide which are fire retardants were incorporated. Test pieces obtained from the resulting resin composition were subjected to a vertical burning test in accordance with UL standards. Both 1/8 inch and 1/16 inch test pieces were found to be acceptable in V-0.
TABLE 2______________________________________Example 7 8 9 10______________________________________Propor- Nylon MXD 6 100 100 100 100tions Nylon 66 13 5 100 20(parts Carbon black 17 5 40 13by Graphite 17 5 40 39weight) Conductive glass fiber 120 30 300 190 Brominated polystyrene -- -- -- 38 Antimony trioxide -- -- -- 19Mechan- Tensile strength 1090 1020 1100 890ical kg/cm.sup.2pro- Tensile elongation % 1.06 0.97 1.41 0.80perties Tensile modulus 149 137 113 180 10.sup.3 kg/cm.sup.2 Flexural strength 1560 1310 1580 1320 kg/cm.sup.2 Flexural modulus 146 111 111 167 10.sup.3 kg/cm.sup.2 Izod impact strength 4.7 3.0 4.5 4.5 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 21.5 19.3 20.5 18.5 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 210 203 210 209 temperature .degree.C.Elec- Volume inherent 0.29 4.0 0.40 0.38trical resistivity .OMEGA. .multidot. cmpro- Electromagneticperties shielding property (electric field 30 MHz) db 58 45 56 56 (electric field 300 MHz) db 75 70 71 72 (magnetic field 30 MHz) db 36 30 33 33 (magnetic field 300 MHz) db 75 68 72 75______________________________________
EXAMPLE 11
One hundred parts of polyphenylene ether resin (Iupiace AV-30 produced by Mitsubishi Gas Chemical Co., Inc.; to be referred to as PPE resin hereinafter), 106 parts of a nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 mm and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 15 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 15 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 300.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a PPE resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 270.degree. C.
Die temperature: 80.degree. C.
Injection and pressure maintenance time: 10 seconds
Cooling time: 25 seconds
Injection pressure: 900 to 1100 kg/cm.sup.2
The results are shown in Table 3.
EXAMPLES 12-13
Example 11 was repeated except that the proportions of the components were varied as shown in Table 3. The results are shown in Table 3.
TABLE 3______________________________________Example 11 12 13______________________________________Propor- PPE resin 100 100 100tions Carbon black 15 5 20(parts Graphite 15 5 20by Conductive glass fiber 106 30 150weight)Mechan- Tensile strength 525 498 547ical kg/cm.sup.2pro- Tensile elongation % 0.83 1.20 0.77perties Tensile modulus 111 97 121 10.sup.3 kg/cm.sup.2 Flexural strength 745 656 778 kg/cm.sup.2 Flexural modulus 85 64 99 10.sup.3 kg/cm.sup.2 Izod impact strength 2.6 3.1 2.4 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 11.8 10.1 12.7 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 102 95 111 temperature .degree.C.Elec- Volume inherent 3.9 .times. above 1.2 .times.trical resistivity .OMEGA. .multidot. cm 10.sup.-1 10.sup.7 10.sup.-1pro- Electromagneticperties shielding property (electric field 30 MHz) db 52 -- 53 (electric field 300 MHz) db 67 -- 68 (magnetic field 30 MHz) db 34 -- 37 (magnetic field 300 MHz) db 73 -- 72______________________________________
EXAMPLE 14
One hundred parts of polybutylene terephthalate resin (TOUGH PET, a product of Mitsubishi Rayon Co., Ltd.; to be abbreviated as PBT resin hereinafter), 106 parts of nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 15 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 15 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 230.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a PBT resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 250.degree. C.
Die temperature: 80.degree. C.
Injection and pressure maintenance time: 10 seconds
Cooling time: 20 seconds
Injection pressure: 800 to 1000 kg/cm.sup.2
The results are shown in Table 4.
EXAMPLES 15-16
Example 14 was repeated except that the proportions of the components were changed as shown in Table 4. The results are shown in Table 4.
TABLE 4______________________________________Example 14 15 16______________________________________Propor- PBT resin 100 100 100tions Carbon black 15 5 20(parts Graphite 15 5 20by Conductive glass fiber 106 30 150weight)Mechan- Tensile strength 628 595 655ical kg/cm.sup.2pro- Tensile elongation % 0.89 1.28 0.82perties Tensile modulus 129 112 140 10.sup.3 kg/cm.sup.2 Flexural strength 820 722 587 kg/cm.sup.2 Flexural modulus 93 70 108 10.sup.3 kg/cm.sup.2 Izod impact strength 3.0 3.6 2.8 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 17 14.5 18.2 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 183 171 194 temperature .degree.C.Elec- Volume inherent 3.5 .times. above 1.0 .times.trical resistivity .OMEGA. .multidot. cm 10.sup.-1 10.sup.7 10.sup.-1pro- Electromagneticperties shielding property (electric field 30 MHz) db 58 -- 62 (electric field 300 MHz) db 76 -- 75 (magnetic field 30 MHz) db 33 -- 39 (magnetic field 300 MHz) db 77 -- 77______________________________________
EXAMPLE 17
One hundred parts of polystyrene resin (Idemitsu Styrol HF10, a product of Idemitsu Petrochemical Co., Ltd.), 106 parts of nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 15 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 15 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 230.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a PBT resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 210.degree. C.
Die temperature: 50.degree. C.
Injection and pressure maintenance time: 10 seconds
Cooling time: 20 seconds
Injection pressure: 800 to 1000 kg/cm.sup.2
The results are shown in Table 5.
EXAMPLES 18-19
Example 17 was repeated except that the proportions of the components were changed as indicated in Table 5. The results are shown in Table 5.
TABLE 5______________________________________Example 17 18 19______________________________________Propor- Polystyrene resin 100 100 100tions Carbon black 15 5 20(parts Graphite 15 5 20by Conductive glass fiber 106 30 150weight)Mechan- Tensile strength 422 400 440ical kg/cm.sup.2pro- Tensile elongation % 0.43 0.62 0.40perties Tensile modulus 138 120 150 10.sup.3 kg/cm.sup.2 Flexural strength 670 590 700 kg/cm.sup.2 Flexural modulus 99 75 115 10.sup.3 kg/cm.sup.2 Izod impact strength 1.6 1.9 1.5 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 8.2 7.0 8.8 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 90 86 94 temperature .degree.C.Elec- Volume inherent 7.6 .times. above 2.2 .times.trical resistivity .OMEGA. .multidot. cm 10.sup.-1 10.sup.7 10.sup.-1pro- Electromagneticperties shielding property (electric field 30 MHz) db 56 -- 57 (electric field 300 MHz) db 73 -- 72 (magnetic field 30 MHz) db 34 -- 38 (magnetic field 300 MHz) db 74 -- 74______________________________________
EXAMPLE 20
One hundred parts of ABS resin (38NP, a product of Japan Synthetic Rubber Co., Ltd.), 106 parts of nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 15 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 15 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 250.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a ABS resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 230.degree. C.
Die temperature: 50.degree. C.
Injection and pressure maintenance time: 10 seconds
Cooling time: 20 seconds
Injection pressure: 800 to 1000 kg/cm.sup.2
The results are shown in Table 6.
EXAMPLES 21-22
Example 20 was repeated except that the proportions of the components were changed as indicated in Table 6. The results are shown in Table 6.
TABLE 6______________________________________Example 20 21 22______________________________________Propor- ABS resin 100 100 100tions Carbon black 15 5 20(parts Graphite 15 5 20by Conductive glass fiber 106 30 150weight)Mechan- Tensile strength 547 518 570ical kg/cm.sup.2pro- Tensile elongation % 0.50 0.72 0.47perties Tensile modulus 128 111 140 10.sup.3 kg/cm.sup.2 Flexural strength 790 700 825 kg/cm.sup.2 Flexural modulus 110 83 128 10.sup.3 kg/cm.sup.2 Izod impact strength 2.2 2.6 2.1 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 8.1 6.9 8.7 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 88 79 94 temperature .degree.C.Elec- Volume inherent 1.3 .times. above 1.0 .times.trical resistivity .OMEGA. .multidot. cm 10.sup.-1 10.sup.7 10.sup.-1pro- Electromagneticperties shielding property (electric field 30 MHz) db 54 -- 56 (electric field 300 MHz) db 66 -- 71 (magnetic field 30 MHz) db 33 -- 37 (magnetic field 300 MHz) db 75 -- 72______________________________________
EXAMPLE 23
One hundred parts of polypropylene resin (Chisso Polypro K-1800, a product of Chisso Corporation), 106 parts of nickel-copper-nickel three layer-coated glass fibers (EMITEC, a product of Asahi Fiber Glass Co., Ltd.) having a fiber length of 3 to 6 and a specific resistance of 10.sup.-3 to 10.sup.-5 ohm-cm, 15 parts of natural scale-like graphite powder (Special CP, a product of Japan Graphite Co., Ltd.) and 15 parts of highly electrically conductive furnace black (Vulcan XC-72, a product of Cabot Corporation) were melt-kneaded in a single screw vent-type extruder at a cylinder temperature of 230.degree. C., and extruded into a strand. The extruded strand was cooled by a water bath, cut to pellets and dried to obtain a PBT resin composition.
The pellets were injection-molded under the following conditions to obtain test pieces which were tested for various properties.
Resin temperature: 210.degree. C.
Die temperature: 50.degree. C.
Injection and pressure maintenance time: 10 seconds
Cooling time: 10 seconds
Injection pressure: 800 to 900 kg/cm.sup.2
The results are shown in Table 7.
EXAMPLES 24-25
Example 23 was repeated except that the proportions of the components were changed as indicated in Table 7. The results are shown in Table 7.
TABLE 7______________________________________Example 23 24 25______________________________________Propor- Polypropylene resin 100 100 100tions Carbon black 15 5 20(parts Graphite 15 5 20by Conductive glass fiber 106 30 150weight)Mechan- Tensile strength 305 289 318ical kg/cm.sup.2pro- Tensile elongation % 1.10 1.59 1.02perties Tensile modulus 84 73 91 10.sup.3 kg/cm.sup.2 Flexural strength 460 405 481 kg/cm.sup.2 Flexural modulus 62 47 72 10.sup.3 kg/cm.sup.2 Izod impact strength 2.7 3.2 2.5 (1/2 inch notched) kg-cm/cm.sup.2 Izod impact strength 12.0 10.2 12.9 (1/2 inch unnotched) kg-cm/cm.sup.2 Heat distortion 107 83 117 temperature .degree.C.Elec- Volume inherent 1.9 .times. above 1.1 .times.trical resistivity .OMEGA. .multidot. cm 10.sup.-1 10.sup.7 10.sup.-1pro- Electromagneticperties shielding property (electric field 30 MHz) db 53 -- 56 (electric field 300 MHz) db 66 -- 72 (magnetic field 30 MHz) db 38 -- 39 (magnetic field 300 MHz) db 74 -- 71______________________________________

Number	Date	Country
61-71052	Mar 1986	JPX
61-71053	Mar 1986	JPX
61-210681	Sep 1986	JPX
61-210682	Sep 1986	JPX
61-210683	Sep 1986	JPX
61-210684	Sep 1986	JPX
61-210685	Sep 1986	JPX

Number	Name	Date
4197218	McKaveney	Apr 1980
4305847	Stoetzer et al.	Dec 1981
4367306	Maeda et al.	Jan 1983
4474685	Annis	Oct 1984
4496475	Abrams	Jan 1985
4528213	Nelson et al.	Jul 1985
4559164	Kostelnik et al.	Dec 1985
4562221	Shigemitsu	Dec 1985
4569786	Deguchi	Feb 1986
4702859	Shimizu et al.	Oct 1987
4704413	Nabeta et al.	Nov 1987
4715989	Sullivan	Dec 1987

Number	Date	Country
61-16942	Jan 1986	JPX
61-16957	Jan 1986	JPX

Electromagnetic wave-shielding thermoplastic resin composition

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