U.S. patent application number 09/919384 was filed with the patent office on 2002-02-28 for stable adhesive composite material made of polyurethane and of another thermoplastic material, a process for its production and a method for its use in motor vehicles.
Invention is credited to Heitkamper, Peter, Rabhofer, Werner, Reihs, Karsten, Schmidt, Manfred, Warth, Holger, Wegener, Dirk.
Application Number | 20020025438 09/919384 |
Document ID | / |
Family ID | 7909223 |
Filed Date | 2002-02-28 |
United States Patent
Application |
20020025438 |
Kind Code |
A1 |
Reihs, Karsten ; et
al. |
February 28, 2002 |
Stable adhesive composite material made of polyurethane and of
another thermoplastic material, a process for its production and a
method for its use in motor vehicles
Abstract
The present invention relates to composite materials made of at
least one composite layer of a polyurethane and of a second
composite layer which is directly bonded to the first layer and
which consists of a thermoplastic material that is different from
the polyurethane of layer A). The polyurethane material of layer A)
is characterized by a residual content of free reaction components
containing ether groups of no more than 400 ppm, and preferably of
no more than 100 ppm. The invention also relates to a process for
the production of these composite materials and to a method of
their use as materials in motor vehicles.
Inventors: |
Reihs, Karsten; (Koln,
DE) ; Rabhofer, Werner; (Koln, DE) ; Warth,
Holger; (Dormagen, DE) ; Wegener, Dirk;
(Monheim, DE) ; Schmidt, Manfred; (Dormagen,
DE) ; Heitkamper, Peter; (Dormagen, DE) |
Correspondence
Address: |
BAYER CORPORATION
PATENT DEPARTMENT
100 BAYER ROAD
PITTSBURGH
PA
15205
US
|
Family ID: |
7909223 |
Appl. No.: |
09/919384 |
Filed: |
July 31, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09919384 |
Jul 31, 2001 |
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09571226 |
May 16, 2000 |
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6296908 |
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Current U.S.
Class: |
428/412 ;
427/407.1; 428/423.5; 428/423.7; 428/424.8 |
Current CPC
Class: |
B32B 2375/00 20130101;
B32B 27/365 20130101; Y10T 428/31551 20150401; Y10T 428/31562
20150401; B32B 5/18 20130101; B32B 27/32 20130101; B32B 27/40
20130101; B32B 2266/0278 20130101; Y10T 428/31739 20150401; Y10T
428/31565 20150401; B32B 2323/10 20130101; C08J 2375/04 20130101;
B32B 2369/00 20130101; Y10T 428/31587 20150401; B32B 2367/00
20130101; Y10T 428/31507 20150401; Y10T 428/31598 20150401; B32B
27/34 20130101; B32B 2323/04 20130101; C08J 5/12 20130101; C09J
175/08 20130101 |
Class at
Publication: |
428/412 ;
427/407.1; 428/423.5; 428/424.8; 428/423.7 |
International
Class: |
B05D 001/36; B32B
027/40; B32B 027/36 |
Foreign Application Data
Date |
Code |
Application Number |
May 26, 1999 |
DE |
19924092.2 |
Claims
What is claimed is:
1. A composite material comprising at least two layers of different
plastics materials which are directly bonded to each other,
comprising: A) at least one layer comprising polyurethane, and B)
at least one layer which is directly bonded to layer A) and
comprising a thermoplastic plastic material which is different from
A), wherein layer A) has a residual content of reaction components
containing ether groups of no more than 400 ppm, which result from
the polyurethane preparation.
2. The composite material of claim 1, wherein layer A) has a
residual content of reaction components containing ether groups of
no more than 100 ppm, which result from the polyurethane
preparation.
3. The composite material of claim 1, wherein the polyurethane of
layer A) of the composite comprises a polyurethane foam or a
polyurethane coating.
4. The composite material of claim 1, wherein the thermoplastic
plastics material of layer B) of the composite comprises a
polycarbonate, a polyester carbonate, a styrene copolymer or of a
corresponding graft copolymer, or mixtures thereof.
5. The composite material of claim 1, wherein the thermoplastic
plastics material of layer B) of the composite comprises a
polyolefin or a polyamide.
6. The composite material of claim 5, wherein said polyolefin is
selected from the group consisting of polyethylene, polypropylene
and ethylene-propylene copolymers.
7. The composite material of claim 5, wherein said polyamide is
selected from the group consisting of preferably polyamide 6 and
polyamide 6.6.
8. The composite material of claim 4, wherein the polyurethane of
layer A) of the composite comprises a polyurethane foam having a
residual content of reaction components containing ether groups of
no more than 100 ppm, and the thermoplastic plastics material of
layer B) of the composite comprises a polycarbonate.
9. A process for the production of a composite material comprising
at least two layers of different plastics materials which are
directly bonded to one another, comprising: (1) applying (A) a
polyurethane-forming reaction system comprising (a) an organic
polyisocyanate and (b) an isocyanate-reactive component, onto (B) a
prefabricated thermoplastic polymer, and (2) allowing the
polyurethane-forming reaction system to fully react, thereby
forming a composite material comprising at least two different
plastics layers, wherein the polyurethane-forming reaction system
has a residual content of reaction components containing ether
groups of at most 400 ppm.
10. The process of claim 8, wherein the polyurethane-forming
reaction system has a residual content of reaction components
containing ether groups of no more than 100 ppm.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention provides composite materials
comprising at least two different plastic material layers directly
bonded to one another, of which one layer consists of polyurethane
and the layer directly bonded to it consists of a different
thermoplastic plastic material.
[0002] It is known that composites comprising a thermoplastic
material and a polyurethane, in particular a polyurethane foam, do
not exhibit adequate bonding adhesion. This bonding adhesion can be
improved by the use of adhesion-promoting layers. This approach is,
however, undesirable for applications in the automobile industry,
where such composite materials are increasingly being employed,
because the required working-tip and recycling processes entail the
use of materials which preferably differ as little as possible.
[0003] Therefore, the object of the present invention was to
adequately improve the bonding adhesion between a layer made of a
polyurethane and a layer directly bonded thereto made of another
thermoplastic material.
SUMMARY OF THE INVENTION
[0004] This object is achieved according to the invention by the
provision of a composite material consisting of at least two layers
directly bonded to one another, comprising
[0005] A. at least one layer comprising a polyurethane formed by
the reaction of (a) at least one polyisocyanate, with (b) at least
one isocyanate-reactive component, and
[0006] B) at least one other (or second) layer which is directly
bonded to the polyurethane layer A), and which comprises a
thermoplastic plastic material that is different from the
polyurethane layer A),
[0007] wherein layer A) has a residual content of reaction
components containing ether groups of no more than 400 ppm, and
preferably of no more than 100 ppm, which result from the
polyurethane preparation.
[0008] This content of reaction components which contain ether
groups are isocyanate-reactive components which did not react with
the isocyanate component in the preparation or formation of the
polyurethane which forms layer A).
[0009] The polyurethanes or polyurethane ureas used in accordance
with the present invention as layer A) are obtained by the reaction
of one or more polyisocyanates, with one or more polyfunctional
compounds containing isocyanate-reactive hydrogen atoms, preferably
polyols.
[0010] Suitable polyisocyanates are preferably those which are
known in polyurethane chemistry and which are conventionally used
therein. In particular, these include aromatic polyisocyanates such
as, for example, 2,4-diisocyanatotoluene, and technical mixtures
thereof with 2,6-diisocyanato-toluene,
4,4'-diisocyanatodiphenylmethane, and mixtures thereof with the
corresponding 2,4'- and 2,2'-isomers, polyisocyanate mixtures of
the diphenylmethane series, those which can be obtained in known
per se manner by phosgenation of aniline/formaldehyde condensation,
the biuret- or isocyanate-containing modification products of these
technical polyisocyanates, and, in particular, NCO prepolymers of
the aforementioned type which are based on these technical
polyisocyanates and on the simple polyols and/or polyether polyols
and/or polyester polyols of the type described below as being
suitable polyfunctional components containing isocyanate-reactive
hydrogen atoms, as well as any mixtures of such isocyanates,
provided that they are sufficiently stable upon storage.
[0011] Among the high-molecular weight, modified polyisocyanates,
the prepolymers which are known in polyurethane chemistry, which
have terminal isocyanate groups and have number average molecular
weights in the range of 400 to 10,000 g/mol, preferably 600 to
8,000 g/mol and more preferably of 800 to 5,000 g/mol, are of
particular interest. These compounds are prepared in the known
manner per se by reacting excess quantities of one or more simple
polyisocyanates, of the type cited above as examples, with one or
more organic compounds containing at least two groups which are
capable of reacting with isocyanate groups, in particular, organic
polyhydroxyl compounds. Suitable polyhydroxyl compounds of this
kind may be simple polyhydric alcohols having number average
molecular weights in the range of 62 to 599 g/mol, preferably 62 to
200 g/mol, such as, for example, ethylene glycol,
trimethylolpropane, 1,2-propanediol, 1,4-butanediol or
2,3-butanediol, and relatively high-molecular weight polyether
polyols and/or polyester polyols of the kind known per se in
polyurethane chemistry, having number average molecular weights of
600 to 8,000 g/mol, preferably 800 to 4,000 g/mol, and containing
at least two, generally 2 to 8, preferably 2 to 4 primary and/or
secondary hydroxyl groups. One may, of course, also use those NCO
prepolymers which have been obtained, for example, from
low-molecular weight (number average) polyisocyanates of the type
cited above by way of example, and from less preferred compounds
possessing groups which are reactive with isocyanate groups, such
as, for example, polythioether polyols, hydroxyl-containing
polyacetals, polyhydroxypolycarbonates, hydroxyl-group containing
polyesteramides ides or hydroxyl-group containing copolymer of
olefinically unsaturated compounds.
[0012] Compounds which are suitable for the preparation of NCO
prepolymers and which possess groups, and in particular, hydroxyl
groups, which are reactive with isocyanate groups include, for
example, the compounds as disclosed in U.S. Pat. No. 4,218,543, the
disclosure of which is herein incorporated by reference. During the
production of the NCO prepolymers, these compounds which possess
groups which are reactive with isocyanate groups are caused to
react with simple polyisocyanates of the kind given above as
examples, with an excess of NCO being maintained The NCO
prepolymers generally have an NCO content of 10 to 25% wt. by
weight, preferably 15 to 22% by weight. It follows from this that,
in the context of the present invention, "NCO prepolymers" and
"prepolymers having terminal isocyanate groups" are understood to
comprise both the reaction products as such and mixtures thereof
with excess quantities of unreacted starting polyisocyanates, which
are frequently also referred to as "semi-prepolymers".
[0013] The polyisocyanate component has an average functionality of
2 to 3, preferably 2.3 to 2.7.
[0014] In order to establish a given NCO content in the isocyanate
component, it may be useful to mix together portions of crude MDI
and an NCO prepolymer. The proportion of material of high
functionality (functionality >4) contained in the crude MDI can
readily be tolerated, provided that the average functionality of 3
up to the isocyanate component is not exceeded.
[0015] Suitable aliphatic diols include those characterized by an
OH value of at least 200 mg KOH/g, preferably at least 500 mg KOH/g
and include the cross-linked chain-extenders which are
conventionally used in polyurethane chemistry, such as ethylene
glycol, diethylene glycol, propylene glycol, dipropylene glycol,
1,4-butanediol, 1,3-propanediol. Diols which have an improved
compatibility with the polyols of the polyfunctional,
isocyanate-reactive component are preferred. Examples of these
include, compounds such as 1,4-butanediol, 1,3-butanediol,
2,3-butanediol, 2-methyl-1,3-propanediol. It is, of course, also
possible to use the aliphatic diols as mixtures with each
other.
[0016] Other suitable polyfunctional, isocyanate-reactive
components include those polyols having an average OH number of 5
to 500 mg KOH/g and an average functionality of 2 to 4. Those
polyols having an average OH number of 10 to 50 mg KOH/g and an
average functionality of 2.7 to 3 are preferred. Examples of such
polyols include polyhydroxypolyethers, which are known in
polyurethane chemistry and are attainable by the alkoxylation of
suitable starter molecules such as, for example, ethylene glycol,
diethylene glycol, 1,4-dihydroxybutane, 1,6-dihydroxyhexane,
dimethylolpropane, glycerol, pentaerythritol, sorbitol or
saccharose. Compounds which can also function as suitable starter
molecules include, for example, ammonia, or amines such as
ethylene-diamine, hexamethylenediamine, 2,4-diaminotoluene or
aniline, aminoalcohols, or phenols such as, for example, bisphenol
A. The alkoxylation can be carried out, for example, using
propylene oxide and/or ethylene oxide in any order.
[0017] Polyester polyols which are also suitable to be used as
polyfunctional isocyanate-reactive components include those of the
type obtainable in known manner per se, by the reaction of one or
more low-molecular weight alcohols with one or more polybasic
carboxylic acids such as, for example, adipic acid, phthalic acid,
hexahydrophthalic acid or tetrahydrophthalic acid, or with the
anhydrides of these acids, preferably, provided that the viscosity
of the isocyanate-reactive component is not too high. A preferred
polyol, which has ester groups, is castor oil. Preparations which
comprise castor oil, such as those which can be obtained by
dissolving resins, for example, aldehydeketone resins, are also
suitable, as are modifications of castor oil and polyols based on
other natural oils.
[0018] Suitable compounds also include, for example, those
high-molecular weight polyhydroxypolyethers in which high-molecular
weight polyadducts or polycondensates or polymers are present in
finely dispersed, dissolved or grafted form. Such modified
polyhydroxyl compounds are generally obtained, for example, when
polyaddition reactions (for example, reactions between
polyisocyanates and aminofunctional compounds) or polycondensation
reactions (for example, between formaldehyde and phenols and/or
amines) are allowed to proceed in situ in the hydroxyl-group
containing compounds. Such processes are known and described in,
for example, DE-AS 1,168,075 and 1,280,142, as well as in DE-A
2,324,134, 2,423,984, 2,512,385, 2,513,815, 2,550,796, 2,550,797,
2,550,833, 2,550,882, 2,633,293 and 2,639,254. According to the
processes described in, for example, U.S. Pat. No. 3,869,413, the
disclosure of which is herein incorporated by reference, or in DE-A
2,550,860, it is even possible to mix a prepared aqueous polymer
dispersion with a polyhydroxyl compound, and subsequently, to
remove the water from the mixture.
[0019] Polyhydroxyl compounds modified by vinyl polymers, such as
those which are obtained by, for example, the polymerization of
styrene and acrylonitrile in the presence of polyethers (as
described in, for example, U.S. Pat. Nos. 3,383,351, 3,304,273,
3,523,093, and 3,110,695, the disclosures of which are herein
incorporated by reference; DE-A 1,152,5369), or of polyether
carbonate polyols (as described in DE-PS 1,769,795, and in U.S.
Pat. No. 3,637,909, the disclosure of which is herein incorporated
by reference), are also suitable for the preparation of
polyurethanes. If polyether polyols are used which have been
modified, in accordance with DE-A 2,442,101, 2,844,922 and
2,646,141, by graft polymerization with vinyl phosphonates, and,
optionally, (meth)acrylonitrile, (meth)acrylamide or OH-functional
(meth)acrylic esters, plastics having a special flame resistance
are produced.
[0020] Representatives of the compounds mentioned above to be used
as polyfunctional isocyanate-reactive compounds are described in,
for example, High Polymers, Vol. XVI, "Polyurethane Chemistry and
Technology", by Saunders-Frisch, Interscience Publishers, New York,
London, Volume 1, 1982, pages 32-42 and pages 44-54 and Volume II,
1984, pages 5-6 and 198-199, and in Kunststoff-Handbuch, Volume
VII, Carl Hanser Verlag, Munich, 1983, for example, on pages
45-61.
[0021] Mixtures of the compounds listed may, of course, also be
used.
[0022] The restriction of the average OH number and of the average
functionality of the isocyanate-reactive component results, in
particular, from the increasing embrittlement of the resulting
polyurethane. In principle, however, the person of ordinary skill
in the art knows the possible ways of influencing the
polymeric/physical properties of polyurethanes, so that NCO
component, the aliphatic diol and the polyol can be advantageously
matched or coordinated with one another in a favorable manner.
[0023] The composite layer A) may be foamed or in solid form such
as, for example, a paint or coating.
[0024] All known per se auxiliary substances and additives such as,
for example, separating agents, blowing agents, fillers, catalysts
and flameproofing agents can be used.
[0025] Auxiliary substances and additives which may optionally be
used include:
[0026] a) water and/or highly volatile inorganic or organic
substances as blowing agents. Suitable organic blowing agents
include, for example, acetone, ethyl acetate, halogen-substituted
alkanes such as methylene chloride, chloroform, ethylidene
chloride, vinylidene chloride, monofluorotrichloro-methane,
chlorodifluoro-methane, dichlorodifluoromethane, as well as butane,
hexane, hexane or diethyl ether; suitable inorganic blowing agents
include, for example, air, CO.sub.2, or N.sub.2O. A blowing action
can also be achieved by adding compounds which decompose at
temperatures above room temperature with the release of gases such
as, for example, nitrogen. Examples of such compounds include azo
compounds such as, for example, azodicarbonamide or
azobisisobutyronitrile. Further examples of blowing agents and
details regarding the use of blowing agents are given in
Kunststoff-Handbuch, Volume VII, edited by Vieweg and Hochtlen,
Carl Hanser Verlag, Munich, 1966, for example, on pages 108 and
109, 453 to 455 and 507 to 510.
[0027] b) Catalysts of the type known per se include, for example,
tertiary amines, such as trimethylamine, tributylamine,
N-methylmorpholine, N-ethylmorpholine,
N,N,N',N'-tetramethylethylenediami- ne,
pentamethyldiethylenetriamine and higher homologues (DE
Offenlegungsschriften 2,624,527 and 2,624,524),
1,4-diazabicyclo-[2.2.2]o- ctane,
N-methyl-N'-(dimethylamino-ethylpiperazine,
bis(dimethyl-aminoalkyl- )piperazine (DE Offenlegungsschriften
2,737,787), N,N-dimethylbenzylamine, N,N-dimethylcyclohexylamine,
N,N-diethylbenzylamine, bis(N,N-diethylaminoethyl) adipate,
N,N,N',N'-tetramethyl-1,3-butanediami- ne,
N,N'-dimethyl-.beta.-phenylethylamine, 1,2-dimethylimidazole,
2-methylimidazole, monocyclic and bicyclic amidines (DE,
Offenlegungsschrift 1,720,633), bis(dialkylamino)alkyl ether (as
described in U.S. Pat. No. 3,330,782 the disclosure of which is
herein incorporated by reference, DE-Auslegungschrift 1,030,558, DE
Offenlegungsschriften 1,804,361 and 2,618,280) as well as tertiary
amines containing amide groups (preferably formamide groups) as in
DE Offenlegungsschriften 2,523,633 and 2,732,292). Known per se
Mannich bases made from secondary amines, such as dimethylamine,
and from aldehydes, preferably formaldehyde, or ketones such as
acetone, methyl ethyl ketone or cyclohexanone, and from phenols,
such as phenol, nonyl phenol or bisphenol, are also suitable
catalysts.
[0028] Tertiary amine catalysts possessing hydrogen atoms which are
active towards isocyanate groups are, for example, triethanolamine,
triisopropyl-amine, N-methyldiethanolamine, N-methyldiethanolamine,
N,N-dimethyl-ethanolamine, their reaction products with alkylene
oxides such as propylene oxide and/or ethylene oxide as well as
secondary-tertiary amines as in DE Offenlegungsschrift
2,732,292.
[0029] Other suitable catalysts include the silaamines containing
carbon-silicon bonds, such as are described, for example, in DE
1,229,290 (believed to correspond to U.S. Pat. No. 3,620,984, the
disclosure of which is herein incorporated by reference), for
example, 2,2,4-trimethyl-2-silamorpholine and
1,3-diethylaminomethyltetramethyldis- iloxane
[0030] Also suitable to be used as catalysts include the
nitrogen-containing bases such as tetraalkylammonium hydroxides, as
are alkali metal hydroxides such as sodium hydroxide, alkali metal
phenolates Such Is sodium phenolate or alkali metal alkoxides such
as sodium methylate. Hexahydrotriazines can also he used as
catalysts (DE Offenlegungsschrift 1,769,043).
[0031] The reaction between NCO groups and isocyanate-reactive
hydrogen atoms is also greatly accelerated by lactam and
azalactams, with an associative component first of all being formed
between the lactam and the compound containing isocyanate-reactive
hydrogen atoms. Such associative compounds and their catalytic
action are described in DE Offenlegungsschriften 2,062,286,
2,062,289 and 2,117,576 (believed to correspond to U.S. Pat. No.
3,758,444, the disclosure of which is herein incorporated by
reference), 2,129,198, 2,330,175 and 2,330,211.
[0032] Organometallic compounds, and in particular, organotin
compounds, can also be used as catalysts. Besides sulfur-containing
compounds such as dioctyltin mercaptide (as described in DE
Auslegeschrift 1,769,367, and in U.S. Pat. No. 3,645,927, the
disclosure of which is herein incorporated by reference), suitable
organotin compounds are chiefly tin(II) salts of carboxylic acids
such as, for example, tin(II) acetate, tin(II) octoate, tin(II)
ethylhexoate and tin(II) laurate, and the tin(IV) compounds such
as, for example, dibutyltin oxide, dibutyltin dichloride,
dibutyltin diacetate, dibutyltin dilaurate, dimethyltin dilaurate,
dibutyltin maleate and dioctyltin diacetate.
[0033] All the above-mentioned catalysts may, of course, be used as
mixtures. Of particular interest here are combinations of
organometallic compounds and amidines, aminopyridines or
hydrazinopyridines (as described in, for example, DE
Offenlegungsschriften 2,434,185, 2,601,802 and 2,603,834).
[0034] Further representatives of catalysts to be used according to
the invention and details regarding the mechanism of action of the
catalysts are described in, for example, Kunststoff-Handbuch,
Volume VII, edited by Vieweg and Hochtlen, Carl Hanser Verlag,
Munich, 1966, on pages 96 to 102.
[0035] The catalysts are generally used in a quantity of between
about 0.001 and l 10% by wt., based on the total quantity of
compounds having at least two hydrogen atoms which are reactive
with isocyanates.
[0036] c) Surface-active additives, such as emulsifiers and foam
stabilizers can also be used in the production of layer A).
Examples of suitable emulsifiers are the sodium salts of castor oil
sulfonates or salts of fatty acids and amines, such as oleic acid
diethylamine or stearic acid diethanolamine. Alkali metal salts or
ammonium salts of sulfonic acids such as, for instance,
dodecylbenzenesulfonic acid or dinaphthyl-methanesulfonic acid, or
of fatty acids such as ricinoleic acid or of polymeric fatty acids
can also be used as surface-active additives.
[0037] Suitable foam stabilizers typically comprise polyether
siloxanes, especially water-soluble representatives thereof. These
compounds are generally built up in such a way that a copolymer of
ethylene oxide and propylene oxide is bonded to a
polydimethylsiloxane group. Such foam stabilizers are described,
for example, in U.S. Pat. Nos. 2,834,748, 2,917,480 and 3,629,308,
the disclosures of which are herein incorporated by reference.
Polysiloxane-polyoxyalkylene copolymers which are multiple branched
via allophanate groups as described in DE Offenlegungsschrift
2,558,523 are of particular interest.
[0038] d) Reaction inhibitors such as, for example, acid-reacting
substances such as hydrochloric acid or organic acid halides, also
cell regulators of the kind known per se such as, for example,
paraffins, fatty alcohols or dimethylpolysiloxanes, as well as
pigments or dyes and flameproofing agents of the kind known per se
such as, for example, tris(chloroethyl) phosphate, tricresyl
phosphate or ammonium phosphate and ammonium polyphosphate, also
stabilizers against the effects of aging and weathering,
plasticizers, and substances which exert a fungistatic and
bacteriostatic effect, as well as fillers such as barium sulfate,
kieselguhr, carbon black and prepared chalk may be included in the
polyurethane forming reaction mixture which is used as layer A) of
the composites of the invention.
[0039] Other examples of surface-active additives and foam
stabilizers which can optionally to be used in the invention, as
well as of cell regulators, reaction inhibitors, stabilizers, flame
retardants, plasticizers, dyes and fillers, and of fungistatic and
bacteriostatic substances, together with details regarding the
method of use and mode of action of these additives, are given in
Kunststoff-Handbuch, Volume VII, edited by Vieweg and Hochtlen,
Carl Hanser Verlag, Munich, 1966, for example, on pages
103-113.
[0040] All the known thermoplastics are suitable for use as
thermoplastic plastic materials which comprises layer B) of the
invention. Thermoplastic polyolefins are preferred and include
compounds such as, for example, polypropylenes or polyethylenes,
polycarbonates, polyester carbonates, styrene copolymers,
rubber-containing graft styrene copolymers, such as ABS polymers,
polyamides and/or thermoplastic mixtures thereof.
[0041] The following polymers are particularly suitable as the
thermoplastic plastic material of layer B):
[0042] Polyolefins such as polyethylene of high density and of low
density, i.e. those having densities in the range of from 0.91
g/cm.sup.3 to 0.97 g/cm.sup.3, which can be prepared by known
processes (Ullmann (4th Ed.) 19, page 167 et seq.,
Winnacker-Kuckler (4th Ed.) 6, 353 to 367, Elias and Vohwinkel,
Neue Polymere Werkstoffe fur die industrielle Anwendung, Munich,
Hanser, 1983.)
[0043] Polypropylenes having weight average molecular weights of
10,000 g/mol to 1,000,000 g/mol, and which can be prepared by known
processes, are also suitable. Methods for preparing these are
described in, for example, Ullmann (5th Ed.) A10, page 615 et seq.;
Houben-Weyl E20/2, page 722 et seq.; Ullmann (4th Ed.) 19, page 195
et seq.; and Kirk-Othmer (3rd Ed.) 16, page 357 et seq.
[0044] Copolymers of the above-mentioned olefins, or with other
.alpha.-olefins, are also suitable to be used as thermoplastic
plastics materials for layer B) of the present invention. Some
suitable examples include:
[0045] polymers of ethylene with butene, hexene and/or octene;
[0046] EVAs (ethylene-vinyl acetate copolymers);
[0047] EEAs (ethylene-ethyl acrylate copolymers);
[0048] EBAs (ethylene-butyl acrylate copolymers);
[0049] EASs (acrylic acid-ethylene acrylate copolymers);
[0050] EVKs (ethylene-vinyl carbazole copolymers);
[0051] EPBs (ethylene-propylene block copolymers);
[0052] EPDMs (ethylene-propylene-diene copolymers);
[0053] PBs (polybutylenes);
[0054] PMPs (polymethylpentenes);
[0055] PIBs (polyisobutylenes);
[0056] NBRs (acrylonitrile-butadiene copolymers);
[0057] polyisoprenes;
[0058] methyl-butylene copolymers;
[0059] and
[0060] isoprene-isobutylene copolymers;
[0061] Methods of preparation of such polymers are described in,
for example, Kunststoff-Handbuch, Volume IV, Munich, Hanser Verlag,
Ullmann (4th Ed.) 19, page 167 et seq.; Winnacker-Kuckler (4th Ed.)
6, 353 to 367; Elias and Vohwinkel, Neue Polymere Werkstoffe,
Munich, Hanser, 1983; and Franck and Biederbick, Kunststoff
Kompendium Wurzburg, Vogel, 1984.
[0062] Thermoplastic plastic materials which according to the
invention are suitable for use as the composite layer B) also
include thermoplastic, aromatic polycarbonates, and in particular,
those based on diphenols corresponding to formula (I): 1
[0063] wherein:
[0064] A represents a single bond, C.sub.1-C.sub.5 alkylene
radical, a C.sub.2-C.sub.5 alkylidene radical , a
C.sub.5-C.sub.6cycloalkylidene radical, --S--, --SO.sub.2--, --O--,
--CO--, or a C.sub.6-C.sub.12 arylene radical, which can optionally
be condensed with other aromatic rings containing hetero atoms;
[0065] B.sup.1 and B.sup.2: each independently represents a
C.sub.1-C.sub.8-alkyl radical, a C.sub.6-C.sub.10 aryl radical, and
preferably a phenyl radical, a C.sub.7-C.sub.12 aralkyl radical,
and preferably a benzyl radical, a halogen atom, and preferably
chlorine or bromine;
[0066] each x: independently represents 0, 1 or 2;
[0067] and
[0068] p represents 1 or 0;
[0069] or an alkyl-substituted dihydroxyphenylcycloalkane
corresponding to formula (II), 2
[0070] wherein
[0071] R.sup.1 and R.sup.2 each independently represent a hydrogen
atom, a halogen atom, and preferably chlorine or bromine, a
C.sub.1-C.sub.8 alkyl radical, a C.sub.5 cycloalkyl radical, a
C.sub.6-C.sub.10aryl radical, and preferably a phenyl radical, and
a C.sub.7-C.sub.12 aralkyl radical, preferably a phenyl
C.sub.1-C.sub.4 alkyl radical, and in particular a benzyl
radical;
[0072] m represents an integer from 4 to 7, preferably 4 or 5;
[0073] R.sup.3 and R.sup.4 are each independently selected for each
Z and each represents, independently of one another, a hydrogen
atom, a C.sub.1-C.sub.6 alkyl radical, and preferably a hydrogen
atom, a methyl radical or an ethyl radical; and
[0074] Z represents carbon, with the proviso that on at least one Z
atom, R.sup.3 and R.sup.4 simultaneously denote an alkyl
radical.
[0075] Example of suitable diphenols corresponding to formula (I)
above include, for example, hydroquinone, resorcinol,
4,4'-dihydroxydiphenyl, 2,2-bis(4-hydroxyphenyl)-propane,
2,4-bis(4-hydroxyphenyl)-2-methylbutane- ,
1,1-bis(4-hydroxyphenyl)cyclohexane,
2,2-bis(3-chloro-4-hydroxyphenyl)pr- opane, 2,2-b
is(3,5-dibromo-4-hydroxyphenyl)propane.
[0076] The preferred diphenols corresponding to formula (I) are
2,2-bis(4-hydroxyphenyl)-propane,
2,2-bis(3,5-dichloro-4-hydroxyphenyl)pr- opane and
1,1-bis(4-hydroxyphenyl)cyclohexane.
[0077] The preferred diphenols corresponding to formula (II) are
the dihydroxydiphenylcycloalkanes having 5- and 6-ring C atoms in
the cycloaliphatic group [(m=4 or 5 in formula (II)], such as, for
example, the diphenols corresponding to the formulae. 3
[0078] wherein:
[0079] 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (formula
(IIa)) is particularly preferred.
[0080] The polycarbonates which are suitable according to the
invention may be branched in known manner. To be more precise, they
are preferably branched by the incorporation of 0.05 to 2.0 mol %,
based on the sum of the diphenols used, of compounds which are
trifunctional or more than trifunctional such as, for example,
those compounds having three or more than three phenolic groups.
Examples of suitable compounds are
[0081] phloroglucinol,
[0082]
4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-2,4,6-dimethyl-2,4,6-
-tri(4-hydroxyphenyl)heptene,
[0083] 1,3,5-tri(4-hydroxyphenyl)benzene,
[0084] 1,1-tri(4-hydroxyphenyl)ethane,
[0085] tri(4-hydroxyphenyl)phenylmethane,
[0086] 2,2-bis(4,4-bis(4-hydroxyphenyl)cyclohexylpropane,
[0087] 2,4-bis(4-hydroxyphenyl)isopropyl)phenol,
[0088] 2,6-bis(2-hydroxy-5'-methylbenzyl)-4-methylphenol,
[0089] 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane,
[0090] hexa(4-(4-hydroxyphenylisopropyl)phenyl)ortho-terephthalic
ester,
[0091] tetra(4-hydroxyphenyl)methane,
[0092] tetra(4-(4-hydroxyphenylisopropyl)phenoxy)methane and
[0093] 1,4-bis(4'-4"-dihydroxytriphenyl)methyl)benzene.
[0094] Some other trifunctional compounds which can be used include
2,4-dihydroxybenzoic acid, trimesic acid, cyanuric chloride and
3,3-bis(3-methyl-4-hydroxyphenyl)-2-oxo-2,3-dyhydroindole.
[0095] In addition to bisphenol A homopolycarbonate, the preferred
polycarbonates are the copolycarbonates of bisphenol A with up to
15 mol %, based on the molar sum of diphenols, of
2,2-bis(3,5-dibromo-4-hydroxy-- phenyl)propane.
[0096] The aromatic polycarbonates to be used for the production of
layer B) of the composite may be partially replaced by aromatic
polyester carbonates.
[0097] Aromatic polycarbonates and/or aromatic polyester carbonates
suitable as a thermoplastic plastic material for layer B) are known
in the literature, and/or can be prepared by methods known in the
literature. For the preparation of aromatic polycarbonates, see,
for example, Schnell, "Chemistry and Physics of Polycarbonates",
Interscience Publishers, 1964.
[0098] Aromatic polycarbonates and/or aromatic polyester carbonates
can be prepared, for example, by the reaction of diphenols with
carbonyl halides, preferably phosgene, and/or with aromatic
dicarboxylic dihalides, preferably benzene dicarboxylic dihalides,
by the phase interface process, optionally, with the use of chain
stoppers and, optionally, with the use of branching agents which
are trifunctional or more than trifunctional.
[0099] Other thermoplastic plastic materials which are suitable for
use as layer B) of the composites of the invention include the
styrene copolymers of one or at least two ethylenically unsaturated
monomers (i.e. vinyl monomers) such as, for example, of styrene,
.alpha.-methylstyrene, ring-substituted styrenes, acrylonitrile,
methacrylonitrile, methyl methacrylate, maleic anhydride,
N-substituted maleimides and (meth)acrylic esters having from 1 to
8 C atoms in the alcohol component.
[0100] The copolymers are resinous and free from rubber.
[0101] The preferred styrene copolymers are those comprising at
least one monomer from the series styrene, .alpha.-methylstyrene
and/or ring-substituted styrene, together with at least one monomer
from the series acrylonitrile, methacrylonitrile, methyl
methacrylate, maleic anhydride and/or N-substituted maleimide.
[0102] It is preferred that the relative weight ratios in the
thermoplastic copolymer are 60 to 95% by weight of the styrene
monomer and 40 to 5% by weight of the other vinyl monomers (based
on 100% by weight of the copolymer).
[0103] Particularly preferred copolymers are those comprising
styrene with acrylonitrile, and, optionally, with methyl
methacrylate, of .alpha.-methylstyrene with acrylonitrile, rural,
optionally, with methyl methacrylate, or of styrene and
.alpha.-methylstyrene with acrylonitrile, and, optionally, with
methyl methacrylate.
[0104] The styrene-acrylonitrile copolymers are known in the art
and can be prepared by radical polymerization, in particular by
emulsion, suspension, solution or bulk polymerization. These
copolymers preferably have weight average molecular weights
(M.sub.w), (as determined by light scattering or by sedimentation)
of between 15,000 and 200,000 g/mol.
[0105] Particularly preferred copolymers also include statistically
built-up copolymers of styrene and maleic anhydride, which can be
prepared from the corresponding monomer, with incomplete reactions,
preferably by a continuous bulk or solution polymerization.
[0106] The proportions of these two components of the statistically
built-up styrene-maleic anhydride copolymers which are suitable
according to the invention can vary within wide limits. The
preferred maleic anhydride content is from 5 to 25% by weight.
[0107] Instead of styrene, the polymers may also contain
ring-substituted styrenes, such as p-methylstyrene,
2,4-dimethylstyrene and other substituted styrenes, such as
.alpha.-methylstyrene.
[0108] The number average molecular weights (number average
{overscore (M)}.sub.n) of the styrene-maleic anhydride copolymers
can vary over a wide range. The range is preferably from 60,000 to
200,000 g/mol. A limiting viscosity of 0.3 to 0.9 (as measured in
dimethylformamide at 25.degree. C.) is preferred for these
products.
[0109] Graft copolymers arc also suitable for use as thermoplastic
plastic materials for the layer B). These include graft copolymers
which have rubber-like elastic properties and are substantially
obtainable from at least two of the following, monomers:
chloroprene, 1,3-butadiene, isoprene, styrene, acrylonitrile,
ethylene, propylene, vinyl acetate and (meth)acrylic esters having
at least 1 to 18 C atoms in the alcohol component. Such polymers of
this type include those as described in, for example, "Methoden der
organischen Chemie" (Houben-Weyl), Vol. 14/1, Georg Thieme Verlag,
Stuttgart, 1961, pp. 393-406. The preferred graft polymers are
partially cross-linked and have gel contents of more than 20% by
weight, preferably more than 40% by weight, and most preferably
more than 60% by weight.
[0110] The preferred graft copolymers include, for example,
copolymers consisting of styrene and/or acrylonitrile and/or alkyl
(meth)acrylates grafted onto polybutadiene, EPDM, butadiene-styrene
copolymers and acrylic rubbers of the type described;
polybutadienes, butadiene/styrene copolymers or
butadiene/acrylonitrile copolymers, polyisobutenes or polyisoprenes
grafted with alkyl acrylates or alkyl methacrylates, vinyl acetate,
acrylonitrile, styrene and/or alkylstyrenes.
[0111] Particularly preferred polymers are, for example, ABS
polymers.
[0112] The graft copolymers can be prepared by known processes,
such as, for example, bulk, suspension, emulsion or bulk-suspension
processes.
[0113] Thermoplastic polyamides which can be used for layer B) of
the composites according to the invention include, for example,
polyamide 66 (polyhexamethylene adipinamide), or polyamides of
cyclic lactams having 5 to 12 C (carbon) atoms, preferably of
lauryl lactam and more preferably of
.epsilon.-caprolactam=polyamide 6 (polycaprolactam), or
copolyamides containing as chief components 6 or 66, or mixtures
thereof with the above-mentioned polyamides as chief component. A
preferred copolyamide is prepared by activated anionic
polymerization, with polycaprolactam as chief component.
[0114] On an industrial scale, the activated anionic polymerization
of lactams to polyamides is carried out by preparing a solution of
catalyst in lactam, optionally, with an impact-resistance modifier
and, separately, a solution of an activator in a lactam, the
compositions of the two solutions generally being such that
combining them in equal proportions produces the required overall
formulation. This is not, however, necessary. Different
compositions can equally well be chosen such as, for example, a
concentrated activator melt and a catalyst melt can be added to a
lactam melt. Depending on compatibilities, other additives can be
added to the activator melt, the catalyst melt or, optionally, to
the lactam melt.
[0115] The polymerization is effected by mixing together the
individual solutions to form the overall formulation at 80.degree.
C. to 200.degree. C., preferably 100.degree. C. to 140.degree.
C.
[0116] The catalyst is an alkali metal lactam or alkaline-earth
lactam, preferably as a solution in lactam, and is most preferably
sodium caprolactamate in .epsilon.-caprolactam.
[0117] The activator for the purpose of the invention can be one of
the N-alkyl lactams or acid chlorides or, preferably, aliphatic
isocyanates, particularly preferably oligomers of hexamethylene
diisocyanate. Both the pure substance and as a solution, for
example, in N-methylpyrrolidone, can be used as the activator. A
solution of the activator is preferred.
[0118] The composites of the invention can be produced in known
manner. Layer B) of the composite which comprises a thermoplastic
polymers is preferably prepared in advance, and the polyurethane
forming reaction system is applied onto the prefabricated
thermoplastic polymer comprising layer B), and allowed to react to
form the polyurethane layer A) of the composite. Depending on the
reactivity of the polyurethane reaction components, these can
already be premixed or can be mixed in the known manner, during the
deposition or application process. Application of the polyurethane
reaction components is typically (and preferably) effected by
spraying, knife-coating or calendering. It is also possible to
produce the composites according to the invention by means of
coextrusion, using known methods.
[0119] In particular, the polyurethane reaction components are
reacted by the single-stage method or the one-step process, by the
prepolymer method, or the semi-prepolymer process.
[0120] During the production of the PU (polyurethane) foamed
plastic, foaming can also be carried out in accordance with the
present invention in closed molds. In this case, the reaction
mixture is introduced into a mold which already contains layer B)
of the composite. Suitable mold materials are metal, for example,
aluminum, or plastics, for example, epoxy resin. The foamable
reaction mixture foams in the mold and forms the composite molding.
Here, the foaming in the mold can be carried out in such a way that
the surface of the molding has a cellular structure. It can also be
carried out in such a way that the molding has a solid skin and a
cellular core. In this embodiment, one can proceed by introducing
foamable reaction mixture into the mold in a quantity such that the
foamed plastic formed just fills the mold. However, one can also
operate by introducing more of the foamable reaction mixture into
the mold than is necessary in order to fill the interior of the
mold with foamed plastic. In the latter case, the operation
involves "overcharging"; such a procedure is generally known in the
art.
[0121] In many cases known per se "external release agents", Such
as silicone oils, are used concomitantly during the foaming in the
mold. It is also possible to use so-called "internal release
agents", optionally, mixed with external release agents.
[0122] Cold-curing foamed plastics can also be produced according
to the invention.
[0123] Foamed plastics can, of course, also be produced by block
foaming or by the per se known double conveyor belt process, which
is preferred for the continuous production of the composites
according to the invention.
[0124] The production of polyurethane composites in a sandwich
construction is also preferred. This type of process can be set up
as a depot-constructing process or as a cover-constructing process.
Both the depot method of construction and the cover method of
construction are known per se. In the depot process (filling method
of construction), two half-shells (such as, for example, covering
layers made of plastic materials) are prepared, then placed in a
mold and the cavity between the shells is foamed with the PU foam.
In the cover method of construction, the core of PU foam is placed
in a mold, and then covered with a suitable covering material such
as, for example, with one of the above-mentioned thermoplastics.
The cover method of construction is preferred for the construction
of sandwich composites.
[0125] To produce solid PU materials, the two PU reaction
components are caused to react by straightforward mixing at room
temperature, as explained above.
[0126] A subsequent additional coating of layer A) can be effected
by the conventional known processes of painting, metallizing, or by
an additional coating with a polymeric layer (such as, for example,
like layer A)).
[0127] The composites according to the invention are used mainly in
the manufacture of motor vehicles, in particular for the interior
lining, for example, as coating material for dashboards or for
covering pillars.
[0128] As used herein, the term molecular weight refers to the
number average molecular weight unless otherwise specified.
[0129] The invention is explained by means of the following
Examples.
EXAMPLES
[0130] The content of unreacted reaction components containing
ether groups in the polyurethane comprising layer A) of the
composite was determined as follows:
[0131] The polymeric layer A) was mechanically separated from the
composite, mechanically comminuted, and extracted with solvents
such as, for example, methylene chloride. It was then possible to
determine the unreacted polyether constituents in the extract by
means of chromatography in combination with NMR spectroscopy or IR
spectroscopy.
[0132] The bonding adhesion was tested in the following way, in
accordance with DIN 53 357.
[0133] The polymeric layer A) was applied in the form of a thin
film to the support layer B), in accordance with the relevant DIN
Standard. The force of separation during the separation of the
composite such as, for example, by a conventional roller peel test
in accordance with DIN 53 357, was then measured.
Example 1
[0134] A polyurethane layer A) having the following composition was
applied to a polymeric support layer B) consisting of polycarbonate
based on bisphenol A (number average molecular weight
(M.sub.n)=12,000 g/mol).
[0135] To this end, a trifunctional polyether prepared from
propylene oxide and ethylene oxide and having a molar mass
(M.sub.n)=7,000 g/mol, was thoroughly mixed with
4,4'-(diisocyanatodiphenylmethane (MDI), and water (1% by eight,
based on the weight of MDI) in stoichiometric proportions (NCO:OH).
To simulate free, unreacted polyether, a polyethylene oxide of the
same molar mass (M.sub.n=7,000 g/mol) and having unreactive end
groups (end groups: diphenylmethyl and methyl) was added in a
concentration of 4,000 ppm. The mixture was then poured immediately
onto the polycarbonate support layer B), with a casting frame
around the polycarbonate support to ensure that a uniform layer
thickness was obtained.
[0136] Following storage of these composites under the conditions
in which the technical product was used (storage for 0 to 14 days
at 80.degree. C. and 80% relative humidity), the polyurethane foam
layer was removed by peeling off sample strips of 20 mm in width
(90.degree. roller peel test), and measuring the separating force
in order to determine the bonding adhesion. After the separation of
the substrate from the polyurethane layer, the concentration of
polyether on the substrate surface was ascertained by X-ray
photoelectron spectroscopy (XPS) via determination of the C--O
content of the Cls line.
[0137] The increase over time in the concentration of polyether on
the separated substrate surface is shown in FIG. 1. It can be seen
from FIG. 2 that an increase in the concentration of polyether at
the interface of the two layers during the course of storage (as
determined via the C--O content by XPS on the separated substrate
surface) lead to a decrease in the bonding adhesion.
Example 2
[0138] Example 1 was repeated, but an unreacted polyether was added
in a concentration of 400 ppm (instead of 4,000 ppm); polyethylene
oxide, M.sub.n=7,000 g/mol, having unreactive end groups: dimethyl
and methyl. The increase over time in the concentration of
polyether on the separated substrate surface rose after 14 days to
C--O contents of 20 atom. % at separating forces of 2.5 N. The
lower concentration of unreacted polyether compared with Example 1
thus showed a distinct decrease in the separating force.
Comparison Example 3
[0139] Example 1 was repeated, without addition of the proportion
of unreacted polyether, for storage times of up to 30 days at
80.degree. C. and 80% relative humidity. The separating force for
the determination of the bonding adhesion was >6 N in all
cases.
[0140] These three Examples show that the bonding adhesion
decreases markedly when the unreacted residual content of the
component containing ether groups rises above 400 ppm.
[0141] Although the invention has been described in detail in the
foregoing for the purpose of illustration, it is to be understood
that such detail is solely for that purpose and that variations can
be made therein by those skilled in the art without departing from
the spirit and scope of the invention except as it may be limited
by the claims.
* * * * *