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(12) Patent Application Publication (10) Pub. No.: US 2006/0020077 A1 Miyoshi Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2006/0020077 A1 Miyoshi Et Al US 20060020077A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2006/0020077 A1 Miyoshi et al. (43) Pub. Date: Jan. 26, 2006 (54) ELECTRICALLY CONDUCTIVE RESIN (30) Foreign Application Priority Data COMPOSITION AND PRODUCTION PROCESS THEREOF Apr. 26, 2000 (JP)...................................... 2000-125081 (76) Inventors: Takaaki Miyoshi, Kimitsu-shi (JP); Publication Classification Kazuhiko Hashimoto, Sodegaura-shi (JP) (51) Int. Cl. C08K 3/04 (2006.01) Correspondence Address: (52) U.S. Cl. .............................................................. 524/495 BRCH STEWART KOLASCH & BRCH PO BOX 747 FALLS CHURCH, VA 22040-0747 (US) (57) ABSTRACT A resin composition comprising a polyamide, a polyphe (21) Appl. No.: 11/203,245 nylene ether, an impact modifier, and a carbon type filler for (22) Filed: Aug. 15, 2005 an electrically conductive use, the filler residing in a phase of the polyphenylene ether. The resin composition of the Related U.S. Application Data present invention has excellent electrical conductivity, flu idity, and an excellent balance of a coefficient of linear (62) Division of application No. 10/240,793, filed on Oct. expansion and an impact resistance, and generation of fines 4, 2002, filed as 371 of international application No. caused by pelletizing thereof can be largely Suppressed PCT/JPO1/O1416, filed on Feb. 26, 2001. when processing of an extrusion thereof is conducted. Patent Application Publication Jan. 26, 2006 US 2006/0020077 A1 FIG. 1 FIG. 2 US 2006/0020077 A1 Jan. 26, 2006 ELECTRICALLY CONDUCTIVE RESIN 0009 From the above-described standpoint, the tech COMPOSITION AND PRODUCTION PROCESS nique wherein improvement in balance of a coefficient of THEREOF linear expansion and an impact resistance can be attained by using a composition Substantially not containing an inor 0001. This application is a Divisional of co-pending ganic filler is required. application Ser. No. 10/240,793 filed on Oct. 4, 2002, and 0010 JP-A-6-287446 discloses a composition compris for which priority is claimed under 35 U.S.C. S. 120; this ing a polyamide, a polyphenylene ether, a styrene type resin application claims priority under 35 USC S 371 of interna and a pigment, wherein yellowing of the composition is tional application no. PCT/JP01/01416, which has an inter reduced by dispersing the pigment in a phase of the polyphe national filing date of Feb. 26, 2001; and this application nylene ether and the Styrene type resin. claims priority of Application No. 2000-125081 filed in Japan on Apr. 26, 2000 under 35 U.S.C. S 119; the entire 0011. However, since the composition obtained by the contents of all are hereby incorporated by reference. technique as described in JP-A-6-287446 contains a large amount of a Styrene type resin, a coefficient of linear TECHNICAL FIELD expansion thereof becomes high and an impact resistance thereof is also largely decreased. Also it has not in the least 0002 The present invention relates to a resin composition electrical conductivity necessary for electroStatic coating, which has excellent electrical conductivity, fluidity, and an and therefore it can not be used for exterior automobile parts excellent balance of a coefficient of linear expansion and an wherein electroStatic coating is possible. impact resistance, and wherein generation of fines caused by 0012 To provide a polymer alloy of a polyphenylene pelletizing is largely Suppressed when processing of extru ether and a polyamide with electrical conductivity, JP-A-2- Sion thereof is conducted, and to a method for producing 201811 discloses a technique of making a carbon black thereof. present mainly in a phase of the polyamide in a mixture of 0003. The composition of the present invention can be a polyphenylene ether, a polyamide, and a carbon black. used in broad fields Such as electrical or electronic parts, OA 0013 However, as in the technique as disclosed in JP-A- parts, parts of vehicles, mechanical parts, etc., and among 2-201811, when a large amount of carbon black is formu them, it can be Suitably used in exterior automobile parts lated in a phase of a polyamide, the polyamide becomes wherein electroStatic coating is possible. extremely fragile and highly viscous, and therefore an impact resistance and fluidity as a composition are greatly BACKGROUND ART worsened. Also, a coefficient of linear expansion thereof is greatly worsened. This is thought to be because an orienta 0004. A polyphenylene ether resin has an excellent tion and a crystallization of the polyamide has been inhibited mechanical property, electrical property, and thermal resis under the influence of an isotropic filler having electrical tance, and has an excellent dimensional Stability, and there conductivity. fore it is used in a broad range. However, a processing property of molding thereof by itself is inferior. In order to 0014 Further, in the above-stated conventional prior art, improve the processing property, the technique of formulat a large amount of Swarf which is called as “fines caused by ing a polyamide therewith is proposed in JP-B-45-997. And pelletizing” (hereinafter sometimes referred to as “fines”) is even thereafter, various improvements have been added generated in a pelletizing step (a step wherein a Strand thereto, and at present, it has become a material which has extruded from an extruder is cut to form pellets) on pro cessing. Usually, it is difficult to remove these fines com many varied uses. pletely. 0005 Having heightened consciousness to environment 0015 These fines caused by pelletizing, in a place of of recent years as a background, to improve fuel cost of fabrication, attach to a pellet drier, a pneumatic transporta automobiles, Study of utilizing a resin as exterior automobile tion lines of a molding machine, a hopper part of a molding materials has been conducted. machine, etc., which necessitates cleaning upon a change of 0006 Especially, in Europe, a need has arisen for mate resin type causing greatly decreased productivity. Therefore, rials which can be electroStatically coated using the same this matter as well as the performance of the above arts has coating line as that used for a Steel plate and thus providing been an item always demanded to be improved. materials with electrical conductivity. 0016. As above, in the conventional prior art, a material 0007 As a conventional prior art concerning exterior which has excellent electrical conductivity, fluidity, and an automobile materials, it is described, for instance, in JP-A- excellent balance of a coefficient of linear expansion and an 2-163158, JP-A-4-372656, and JP-A-6-306275, that high impact resistance, and wherein generation of fines caused by balance of a coefficient of linear expansion and an impact pelletizing is greatly Suppressed, has not heretofore been resistance is important, and a composition comprising a available. polyamide resin, a polyphenylene ether, and an inorganic 0017 Moreover, exterior automobile materials have filler is useful. many necessary properties in addition to the above-de 0008 However, in the above-described conventional Scribed characteristic properties, and for instance, JP-A-60 prior art, Since the coefficient of linear expansion is 65035 describes that high adhesion properties with a coating decreased by adding the inorganic filler, Sufficient level of an are also required. impact resistance was not attained, and it has not been 0018. The present invention aims to solve the problems afforded to a practical use, which has been the actual Status. which have not been solved by the above stated prior art. US 2006/0020077 A1 Jan. 26, 2006 0019. It is therefore an object of the present invention to cyclohexane, 1,4-bisaminomethyl cyclohexane, m-phe provide a resin composition which has excellent electrical nylene diamine, p-phenylene diamine, m-xylylene diamine, conductivity, fluidity, and an excellent balance of a coeffi and p-xylylene diamine, are mentioned. cient of linear expansion and an impact resistance, and 0031. As the dicarboxylic acid, an aliphatic, an alicyclic, wherein generation of fines caused by pelletizing is largely and an aromatic dicarboxylic acid are exemplified, and Suppressed. Specifically, adipic acid, Suberic acid, azelaic acid, Sebacic acid, dodecanoic diacid, 1,1,3-tridecanoic diacid, 1,3-cyclo DISCLOSURE OF THE INVENTION hexane dicarboxylic acid, terephthalic acid, isophthalic acid, 0020. The present inventors have intensively studied to naphthalene dicarboxylic acid, dimmer acid, etc., are men Solve the problem as described above, and as a result, tioned. Surprisingly, they have found that, by making a carbon type 0032. As the lactams, specifically, e-caprolactam, enan filler for an electrically conductive use reside in a phase of thlactam, co-laurocaprolactam, etc., are mentioned. a polyphenylene ether, a resin composition which has excel lent electrical conductivity, fluidity, and an excellent balance 0033. Further, as the aminocarboxylic acid, specifically, of a coefficient of linear expansion and an impact resistance, e-aminocaproic acid, 7-aminoheptanoic acid, 8-aminooc and wherein generation of fines caused by pelletizing is tanoic acid, 9-aminononanoic acid, 11-aminoundecanoic largely Suppressed, can be obtained. Thus, the present inven acid, 12-aminododecanoic acid, 13-aminotridecanoic acid, tion has been accomplished. etc., are mentioned. 0021. The resin composition of the present invention 0034. In the present invention, any of copolymer polya comprises a polyamide, a
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