U.S. patent application number 12/191399 was filed with the patent office on 2009-03-26 for glass fiber reinforced polycarbonate molding compositions.
This patent application is currently assigned to Bayer MaterialScience AG. Invention is credited to Michael Erkelenz, Andreas SEIDEL, Eckhard Wenz.
Application Number | 20090082516 12/191399 |
Document ID | / |
Family ID | 39941790 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090082516 |
Kind Code |
A1 |
SEIDEL; Andreas ; et
al. |
March 26, 2009 |
GLASS FIBER REINFORCED POLYCARBONATE MOLDING COMPOSITIONS
Abstract
The invention relates to glass fiber reinforced polycarbonate
compositions and molding compositions of the present inventor and
distinguished by high rigidity, high flowability, high processing
stability, good chemical resistance and good aging resistance
vis-a-vis the effects of light and heat compared with the prior
art. The present invention also relates to the use of the
compositions for the production of shaped articles and to shaped
articles comprising the compositions according to the
invention.
Inventors: |
SEIDEL; Andreas; (Dormagen,
DE) ; Erkelenz; Michael; (Duisburg, DE) ;
Wenz; Eckhard; (Koln, DE) |
Correspondence
Address: |
Baker Donelson Bearman, Caldwell & Berkowitz, PC
555 Eleventh Street, NW, Sixth Floor
Washington
DC
20004
US
|
Assignee: |
Bayer MaterialScience AG
Leverkusen
DE
|
Family ID: |
39941790 |
Appl. No.: |
12/191399 |
Filed: |
August 14, 2008 |
Current U.S.
Class: |
524/494 ;
524/504 |
Current CPC
Class: |
C08L 69/005 20130101;
C08K 9/08 20130101; C08L 25/12 20130101; C08L 69/00 20130101; C08L
69/00 20130101; C08L 69/005 20130101; C08L 2666/04 20130101; C08L
2666/04 20130101 |
Class at
Publication: |
524/494 ;
524/504 |
International
Class: |
C08K 3/40 20060101
C08K003/40 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 16, 2007 |
DE |
10 2007 038 438.8 |
Claims
1. A composition comprising A) 10 to 85 parts by weight a
polycarbonate, and/or a polyester carbonate, B) 10 to 50 parts by
weight rubber-free vinyl copolymer, C) 5 to 50 parts by weight of
sized glass fiber, wherein the size comprises an epoxy polymer, D)
0 to 2 parts by weight of a rubber-modified graft polymer, and E) 0
to 10 parts by weight of a polymer additive, the composition being
free from rubber-modified polymers which differ from component
D).
2. A composition according to claim 1, comprising 15 to 40 parts by
weight of said rubber-free vinyl copolymer.
3. A composition according to claim 1, comprising 20 to 35 parts by
weight of rubber-free vinyl copolymer.
4. A composition according to claim 1, comprising 0 to 1 parts by
weight of a rubber-modified graft polymer.
5. A composition according to claim 1, which is free from
rubber-modified graft polymer.
6. The composition according to claim 1, wherein component C is a
sized glass fiber with C.1 a glass fiber comprising at least one
component selected from the group consisting of continuous strands,
long glass fibers and chopped glass strands, C.2 a size containing
an epoxy polymer, and C.3 optionally an adhesion promoter.
7. A composition according to claim 6 comprising as component C, a
glass fiber with a size C.2 consisting essentially of: C.2.1 50 to
100 wt. %, based on the total weight of C.2, of an epoxy polymer,
and C.2.2 0 to 50 wt. %, based on the total weight of C.2, of at
least one polymer selected from the group consisting of the
polyurethanes, polyolefins, acrylate-containing polymers,
styrene-containing polymers and polyamides.
8. A composition according to claim 7, wherein the epoxy polymer
C.2.1 comprises an epoxy resin made from C.2.1.1 epichlorohydrin
and C.2.1.2 an alcohol, which has at least two hydroxyl groups.
9. A composition according to claim 8, in which bisphenol A is used
as the alcohol C.2.1.2.
10. A composition according to claim 1, wherein the sized glass
fiber according to component C has a carbon content of 0.1 to 1 wt.
%.
11. A composition according to claims 1, wherein the glass fiber
according to component C has an average diameter of 5 to 25
.mu.m.
12. A composition according to claims 1, wherein component E
comprises at least one additive selected from the group consisting
of flame retardants, anti-drip agents, lubricants and mold release
agents, nucleating agents, antistatic agents, stabilisers, fillers,
reinforcing materials other than component C, dyes and
pigments.
13. A composition according to claim 1, wherein component B is a
rubber-free vinyl copolymer of B.1 70 to 80 wt. %, based on the
total weight of component B, of at least one monomer selected from
the group consisting of the vinyl aromatics and ring-substituted
vinyl aromatics and B.2 20 to 30 wt. %, based on the total weight
of component B, of at least one monomer selected from the group
consisting of the vinyl cyanides, (meth)acrylic acid
(C.sub.1-C.sub.8) alkyl esters, unsaturated carboxylic acids and
derivatives of unsaturated carboxylic acids.
14. A composition according to claim 13, wherein component B.1 is
styrene and component B.2 is acrylonitrile.
15. A composition according to claim 1, comprising as component D,
a rubber-based graft polymer which is substantially free from
double bonds.
16. A composition according to claim 15, comprising as component D,
a rubber-based graft polymer selected from the group consisting of
acrylate rubber, silicone rubber and silicone-acrylate composite
rubber.
17. A method for the production of a shaped article comprising
employing a composition according to claim 1.
18. A shaped article comprising a composition according to claim 1.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from DE 102007038438 filed
Aug. 16, 2007, the content of which is incorporated herein by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The invention relates to glass fiber reinforced
polycarbonate compositions and molding compositions, which are
distinguished by high rigidity, high flowability, high processing
stability, good chemical resistance and good aging resistance
vis-a-vis the effects of light and heat compared with the prior
art.
[0003] 1. Description of Related Art
[0004] Compositions containing polycarbonate and rubber-modified
styrene polymers, such as e.g. ABS (acrylonitrile-butadiene-styrene
polymers), are known for their balance of excellent mechanical
properties and good melt flowability. They are used in many
different areas of application, for example, in car construction,
in the building sector and in housings for office equipment and
domestic appliances.
[0005] A low coefficient of thermal expansion and good dimensional
stability, as well as shape stability and high rigidity, are
generally needed to produce moulded parts with a large surface
area. These properties can be achieved by the addition of fillers
or reinforcing materials. High moduli of elasticity can be obtained
particularly by adding fibrous reinforcing materials. However, the
addition of the fillers or reinforcing materials generally has a
disadvantageous effect on the toughness and particularly on the
flow properties of the polymer melts, i.e. the processing
characteristics. As a result, increased processing temperatures are
usually required, which entails a further reduction in material
toughness. The practicable degrees of filling with reinforcing
material, and thus the material rigidities that can be achieved
are, in effect, limited by these parameters, and moulded parts with
large surface areas and very thin walls are often impossible to
produce with those polycarbonate compositions that correspond to
the prior art described below. For these areas of application there
is a demand for such polycarbonate compositions to be produced with
improved flowability and a higher modulus of elasticity, and with a
toughness which is good over a broad processing window and stable
vis-a-vis heat aging. Since moulded parts produced from
compositions of this type are often painted and, in the context of
the post-treatment needed in connection with this, generally come
into contact with chemicals, such as e.g. paint solvents, there is
a further demand for adequate chemical resistance. For this reason,
the use of low molecular weight polycarbonates to improve the
polymer melt flowability is out of the question, since these
usually lead to a negative effect on stress cracking
resistance.
[0006] Rubber-modified vinyl copolymers containing glass fiber
reinforced polycarbonate compositions are known from the prior
art.
[0007] WO-A 00/39210 discloses polycarbonate compositions
containing polycarbonate, styrene resin, phosphoric ester and
reinforcing agents (e.g. glass fibers), as well as optionally a
graft polymer based on a silicone-acrylate composite rubber with a
vinyl monomer-based graft shell, which are distinguished by
improved hydrolysis resistance, good flame resistance and by
improved mechanical properties. The styrene resins employed contain
a rubber-based graft polymer. No glass fiber sizes are
disclosed.
[0008] EP-A 1 240 250 discloses polycarbonate compositions
containing 10-93 wt. % polycarbonate, 3-50 wt. % rubber
elastic-based graft polymer, 3- 50 wt. % thermoplastic copolymer
and 1-20 wt. % of a mixture of particulate mineral and fibrous
fillers, which are distinguished by reduced thermal expansion, good
toughness, good dimensional stability and high flowability together
with improved surface quality in the region of the gate.
[0009] EP-A 0 624 621 discloses polycarbonate compositions
containing 10-80 wt. % polycarbonate, 10-80 wt. % rubber-modified
graft polymer and 5-50 wt. % glass fibers with a coating containing
polyolefin wax, which are distinguished by improved toughness and
ductility.
[0010] EP-A 0 345 652 discloses polycarbonate compositions
containing 10-75 wt. % polycarbonate, 10-50 wt. % rubber-based
graft copolymer, up to 50 wt. % styrene copolymer, 0.5-50 wt. %
terpolymer containing tert-butyl (meth)acrylate and 5 to 50 wt. %
reinforcing agents (e.g. glass fibers), which are distinguished by
high strength, good toughness and by low yellowing. The glass
fibers used in this cited application are generally provided with a
size and an adhesion promoter, but the composition of the size is
not disclosed here.
[0011] The prior art documents cited above do not, however,
disclose any compositions that contain polycarbonate, rubber-free
vinyl copolymers (e.g. styrene-acrylonitrile copolymers) and no
rubber-containing graft polymer or only very small quantities
thereof (i.e. up to 2 wt. %).
[0012] Disadvantages of the compositions described in the prior
art, which contain rubber-modified graft polymers in quantities of
more than 2 wt. %, are too low a melt flowability and inadequate
aging resistance.
[0013] Compositions containing polycarbonate, glass fibers and
rubber-free vinyl copolymer, which contain no rubber-modified vinyl
copolymers or only very small quantities thereof, are also known
from the prior art.
[0014] WO-A 84/04317 discloses polycarbonate compositions
containing polycarbonate, styrene resin, unsized glass fibers and a
hydrogen polysiloxane, which are distinguished by high impact
resistance and a high modulus.
[0015] EP-A 0 647 679 discloses polycarbonate compositions
containing special copolycarbonates with bisphenol and resorcinol
monomer units, rubber-containing copolymer and/or copolymer of
vinyl aromatic and cyanated vinyl monomer components as well as
inorganic filler (e.g. glass fibers), which are distinguished by
good flowability, high impact resistance and good surface quality.
No glass fiber sizes are disclosed.
[0016] EP-A 1 038 920 discloses polycarbonate compositions
substantially consisting of a special aromatic polycarbonate
produced by melt polymerization, a styrene-based resin (e.g. a
styrene-acrylonitrile copolymer with a styrene content of at least
20%, preferably at least 30%), a reinforcing fibrous filler and
optionally an elastomeric polymer, which are distinguished by
improved moist heat resistance and improved toughness. It is
disclosed that the glass fibers used may be coated with a size made
of polymers (such as e.g. epoxy resin, urethane resin, acrylic
resin, nylon resin etc.). In the examples, only compositions
containing polyurethane-sized glass fibers are disclosed.
[0017] WO-A 2006/040087 discloses polycarbonate compositions
containing polycarbonate, a terpolymer of styrene, acrylonitrile
and maleic anhydride, and long glass fibers, which are
distinguished by a combination of improved tensile strength,
modulus of elasticity and impact resistance. In addition, these
compositions preferably contain at least one polymer selected from
the group of the rubber-containing graft polymers and rubber-free
copolymers. It is disclosed that the long glass fibers may be
surface-modified with a size, without any information on the
chemistry of the size being disclosed.
[0018] Although the glass fiber reinforced polycarbonate
compositions based on rubber-free styrene resins disclosed in the
prior art do generally exhibit good melt flowability and aging
resistance, they are, however, distinguished by inadequate
toughness for certain areas of application, particularly at higher
processing temperatures, and by unsatisfactory chemical resistance
and rigidity.
SUMMARY OF THE INVENTION
[0019] This invention was therefore based, inter alia, on an object
of providing free-flowing polycarbonate compositions which are
resistant to aging vis-a-vis the effects of heat and light, with
improved processing stability (i.e. stable toughness even at higher
processing temperatures), improved rigidity and improved chemical
resistance.
[0020] Surprisingly, it has been found that this object can be
achieved by providing a composition comprising: [0021] A) 10 to 85
parts by weight, preferably 30 to 80 parts by weight, especially 40
to 70 parts by weight polycarbonate, polyester carbonate or a
mixture thereof, [0022] B) 10 to 50 parts by weight, preferably 15
to 40 parts by weight, especially 20 to 35 parts by weight
rubber-free vinyl copolymer, [0023] C) 5 to 50 parts by weight,
preferably 7 to 35 parts by weight, especially 8 to 25 parts by
weight of a sized glass fiber, wherein the size comprises an epoxy
polymer, [0024] D) 0 to 2 parts by weight, preferably 0 to 1 parts
by weight, particularly preferably 0 parts by weight of
rubber-modified graft polymers (in other words, the composition is
preferably free of rubber-modified graft polymers), and [0025] E) 0
to 10 parts by weight, preferably 0.01 to 5 parts by weight,
especially 0.1 to 3 parts by weight of commercial polymer
additives,
[0026] the composition further being free from rubber-modified
polymers which differ from component D).
[0027] The sum of the components A+B+C+D+E is standardized to 100
parts by weight.
[0028] Additional objects, features and advantages of the invention
will be set forth in the description which follows, and in part,
will be obvious from the description, or may be learned by practice
of the invention. The objects, features and advantages of the
invention may be realized and obtained by means of the
instrumentalities and combination particularly pointed out in the
appended claims.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Component A
[0029] Aromatic polycarbonates and/or aromatic polyester carbonates
according to component A which are suitable according to the
invention are known for example, from the literature and/or can be
produced by processes known from the literature (for the production
of aromatic polycarbonates, cf. for example Schnell, "Chemistry and
Physics of Polycarbonates", Interscience Publishers, 1964, and
DE-AS 1 495 626, DE-A 2 232 877, DE-A 2 703 376, DE-A 2 714 544,
DE-A 3 000 610, DE-A 3 832 396; for the production of aromatic
polyester carbonates, e.g. DE-A 3 077 934), the contents of which
is incorporated herein by reference in their entireties.
[0030] The production of aromatic polycarbonates can take place
e.g. by transesterification of diphenols with carbonic acid
halides, preferably phosgene, and/or with aromatic dicarboxylic
acid dihalides, preferably benzenedicarboxylic acid dihalides, by
the interfacial polycondensation process, optionally using chain
terminators, for example monophenols, and optionally using
branching agents which are trifunctional or more than
trifunctional, for example triphenols or tetraphenols. Production
via a melt polymerization process by reaction of diphenols with,
for example, diphenyl carbonate is also possible.
[0031] Diphenols for the production of the aromatic polycarbonates
and/or aromatic polyester carbonates are preferably those of the
formula (I)
wherein [0032] A is a single bond, C.sub.1 to C.sub.5 alkylene,
C.sub.2 to C.sub.5 alkylidene, C.sub.5 to C.sub.6 cycloalkylidene,
--O--, --SO--, --CO--, --S--, --SO.sub.2--, C.sub.6 to C.sub.12
arylene, on to which further aromatic rings optionally containing
heteroatoms may be condensed, or a radical of the formula (II) or
(III)
[0032] ##STR00001## [0033] B in each case is C.sub.1 to C.sub.12
alkyl, preferably methyl, or halogen, preferably chlorine and/or
bromine, [0034] x in each case independently of one another, is 0,
1 or 2, [0035] p is 1 or 0 and [0036] R.sup.5 and R.sup.6 are
selected individually for each X.sup.1 and independently of one
another denote hydrogen or C.sub.1 to C.sub.6 alkyl, preferably
hydrogen, methyl or ethyl, [0037] X.sup.1 denotes carbon and [0038]
m denotes an integer from 4 to 7, preferably 4 or 5, with the
proviso that on at least one atom X.sup.1, R.sup.5 and R.sup.6 are
simultaneously alkyl.
[0039] Preferred diphenols include hydroquinone, resorcinol,
dihydroxydiphenols, bis(hydroxyphenyl)-C.sub.1-C.sub.5-alkanes,
bis(hydroxyphenyl)-C.sub.5-C.sub.6-cycloalkanes, bis(hydroxyphenyl)
ethers, bis(hydroxyphenyl) sulfoxides, bis(hydroxyphenyl) ketones,
bis(hydroxyphenyl) sulfones and .alpha.,.alpha.-bis(hydroxyphenyl)
diisopropylbenzenes and ring-brominated and/or ring-chlorinated
derivatives thereof.
[0040] Particularly preferred diphenols are 4,4' dihydroxydiphenyl,
bisphenol A, 2,4-bis(4-hydroxyphenyl)-2-methylbutane,
1,1-bis(4-hydroxyphenyl)-cyclohexane,
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane,
4,4'-dihydroxydiphenyl sulfide, 4,4'-dihydroxydiphenyl sulfone and
di- and tetrabrominated or chlorinated derivatives thereof, such
as, for example, 2,2-bis(3-chloro-4-hydroxyphenyl)propane,
2,2-bis(3,5-dichloro-4-hydroxyphenyl)propane or
2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane.
2,2-Bis(4-hydroxyphenyl)propane (bisphenol A) is especially
preferred.
[0041] The diphenols may be employed individually or as any desired
mixtures. The diphenols are known from the literature or obtainable
by processes known from the literature.
[0042] Chain terminators which are suitable for the production of
the thermoplastic, aromatic polycarbonates are, for example,
phenol, p-chlorophenol, p-tert-butylphenol or 2,4,6-tribromophenol,
and also long-chain alkylphenols, such as
4-[2-(2,4,4-trimethylpentyl)]phenol, 4-(1,3-tetramethylbutyl)phenol
according to DE-A 2 842 005 or monoalkylphenol or dialkylphenols
having a total of 8 to 20 carbon atoms in the alkyl substituents,
such as 3,5-di-tert.-butylphenol, p-iso-octylphenol,
p-tert.-octylphenol, p-dodecylphenol and
2-(3,5-dimethylheptyl)phenol and 4-(3,5-dimethylheptyl)phenol. The
amount of chain terminators to be employed is generally between 0.5
mole % and 10 mole %, based on the sum of the moles of the
particular diphenols employed.
[0043] The thermoplastic, aromatic polycarbonates may be branched
in a known manner, and preferably by incorporation of 0.05 to 2.0
mole %, based on the sum of the diphenols employed, of compounds
which are trifunctional or more than trifunctional, for example
those having three and more phenolic groups.
[0044] Both homopolycarbonates and copolycarbonates are suitable.
It is also possible for 1 to 25 wt. %, preferably 2.5 to 25 wt. %,
based on the total amount of diphenols to be employed, of
polydiorganosiloxanes having hydroxyaryloxy end groups to be
employed for the production of copolycarbonates according to the
invention according to component A. These are known (U.S. Pat. No.
3,419,634) and can be produced by processes known from the
literature. The preparation of copolycarbonates containing
polydiorganosiloxanes is described in DE-A 3 334 782.
[0045] Preferred polycarbonates are, in addition to the bisphenol A
homopolycarbonates, the copolycarbonates of bisphenol A with up to
15 mole %, based on the sum of the moles of diphenols, of other
diphenols mentioned as preferred or particularly preferred, in
particular 2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane.
[0046] Aromatic dicarboxylic acid dihalides for the production of
aromatic polyester carbonates are preferably the diacid dichlorides
of isophthalic acid, terephthalic acid, diphenyl
ether-4,4'-dicarboxylic acid and of naphthalene-2,6-dicarboxylic
acid. Mixtures of the diacid dichlorides of isophthalic acid and of
terephthalic acid in a ratio of between 1:20 and 20:1 are
particularly preferred.
[0047] A carbonic acid halide, preferably phosgene, is additionally
used as a bifunctional acid derivative in the production of
polyester carbonates.
[0048] Possible chain terminators for the preparation of the
aromatic polyester carbonates are, in addition to the monophenols
already mentioned, also chlorocarbonates thereof as well as the
acid chlorides of aromatic monocarboxylic acids, which may
optionally be substituted by C.sub.1 to C.sub.22 alkyl groups or by
halogen atoms, as well as aliphatic C.sub.2 to C.sub.22
monocarboxylic acid chlorides.
[0049] The quantity of chain terminators is in each case 0.1 to 10
mole %, based on the moles of diphenol in the case of the phenolic
chain terminators and on the moles of dicarboxylic acid dichloride
in the case of monocarboxylic acid chloride chain terminators.
[0050] The aromatic polyester carbonates may also contain
incorporated aromatic hydroxycarboxylic acids.
[0051] The aromatic polyester carbonates may be either linear or
branched in a known manner (in this context see DE-A 2 940 024 and
DE-A 3 007 934, incorporated herein by reference in their
entireties).
[0052] Branching agents which may be used include, for example,
acyl chlorides which are trifunctional or more than trifunctional,
such as trimesic acid trichloride, cyanuric acid trichloride,
3,3',4,4'-benzophenonetetracarboxylic acid tetrachloride,
1,4,5,8-naphthalenetetracarboxylic acid tetrachloride or
pyromellitic acid tetrachloride, in quantities of from 0.01 to 1.0
mole % (based on the dicarboxylic acid dichlorides employed), or
phenols which are trifunctional or more than trifunctional, such as
phloroglucinol, 4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)hept-2-ene,
4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)heptane,
1,3,5-tri-(4-hydroxyphenyl)benzene,
1,1,1-tri-(4-hydroxyphenyl)ethane,
tri-(4-hydroxyphenyl)phenylmethane,
2,2-bis[4,4-bis(4-hydroxyphenyl)cyclohexyl]propane,
2,4-bis(4-hydroxyphenylisopropyl)phenol,
tetra-(4-hydroxyphenyl)methane,
2,6-bis(2-hydroxy-5-methylbenzyl)-4-methyl-phenol,
2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)propane,
tetra-(4-[4-hydroxyphenylisopropyl]phenoxy)methane and
1,4-bis[4,4'-dihydroxytriphenyl)methyl]-benzene, in amounts of from
0.01 to 1.0 mole %, based on the diphenols employed. Phenolic
branching agents may be initially introduced into the reaction
vessel with the diphenols, and acid chloride branching agents may
be introduced together with the acid dichlorides.
[0053] The proportion of carbonate structural units in the
thermoplastic, aromatic polyester carbonates may be varied as
desired. Preferably, the content of carbonate groups is up to 100
mole %, especially up to 80 mole %, particularly preferably up to
50 mole %, based on the sum of ester groups and carbonate groups.
Both the ester and the carbonate content of the aromatic polyester
carbonates may be present in the polycondensate in the form of
blocks or in random distribution.
[0054] In a preferred embodiment, the component A has a
weight-average molecular weight Mw (determined by GPC, light
scattering or sedimentation) of 23 000 g/mole to 40 000 g/mole,
preferably of 24 000 g/mole to 35 000 g/mole, especially of 25 000
to 32 000 g/mole.
Component B
[0055] In a preferred embodiment, component B is a rubber-free
vinyl copolymer of [0056] B.1 70 to 80 wt. %, preferably 72 to 78
wt. %, especially 75 to 78 wt. % (based in each case on component
B), of at least one monomer selected from the group of the vinyl
aromatics (such as, for example, styrene and .alpha.-methylstyrene)
or ring-substituted vinyl aromatics (such as, for example,
p-methylstyrene and p-chlorostyrene) and [0057] B.2 20 to 30 wt. %,
preferably 22 to 28 wt. %, especially 22 to 25 wt. % (based in each
case on component B), of at least one monomer selected from the
group of the vinyl cyanides (such as, for example, unsaturated
nitriles, such as acrylonitrile and methacrylonitrile),
(meth)acrylic acid (C.sub.1-C.sub.8) alkyl esters (such as, for
example, methyl methacrylate, n-butyl acrylate and tert.-butyl
acrylate), unsaturated carboxylic acids and derivatives of
unsaturated carboxylic acids (for example maleic anhydride and
N-phenylmaleimide).
[0058] The copolymers B are resinous, thermoplastic and
rubber-free. Particularly preferably, component B is a rubber-free
copolymer of styrene (B.1) and acrylonitrile (B.2).
[0059] Copolymers of this type are known and can be produced by
free-radical polymerization, especially by emulsion, suspension,
solution or bulk polymerization.
[0060] The (co)polymers preferably possess average molecular
weights (M.sub.w) (weight average, determined by GPC, light
scattering or sedimentation) between 15 000 and 250 000 g/mole,
particularly between 50 000 and 200 000 g/mole, especially between
80 000 and 160 000 g/mole.
Component C
[0061] In a preferred embodiment, component C is a sized glass
fiber with [0062] C. 1 a glass fiber selected from at least one
component from the group comprising and advantageously consisting
of continuous strands (rovings), long glass fibers and chopped
glass strands, [0063] C.2 a size containing an epoxy polymer (in
other words, the "size" fills pores in the glass fiber or provides
a covering or glaze), and [0064] C.3 optionally an adhesion
promoter.
[0065] Size C.2 and adhesion promoter C.3 are preferably employed
in component C in an amount such that the carbon content measured
in component C is 0.1 to 1 wt. %, preferably 0.2 to 0.8 wt. %,
particularly preferably 0.3 to 0.7 wt. %.
[0066] The glass fibers according to component C.1 are preferably
made from E-, A- or C-glass. The diameter of the glass fibers is
preferably 5 to 25 .mu.m, particularly preferably 6 to 20 .mu.m,
most preferably 7 to 15 .mu.m. The long glass fibers preferably
have a length of 5 to 50 mm, particularly preferably 5 to 30 mm,
most preferably 7 to 25 mm. Long glass fibers are described e.g. in
WO-A 2006/040087, the content of which is incorporated herein by
reference. At least 70 wt. % of the glass fibers in the chopped
glass strands preferably have a length of at least about 60
.mu.m.
[0067] The size C.2 preferably comprises or consists of [0068]
C.2.1 50 to 100 wt. %, preferably 70 to 100 wt. %, particularly
preferably 80 to 100 wt. % (based on C.2 in each case) epoxy
polymer and [0069] C.2.2 0 to 50 wt. %, preferably 0 to 30 wt. %,
particularly preferably 0 to 20 wt. % (based on C.2 in each case)
of one or more other polymers.
[0070] Most preferably, in one embodiment the size C.2 consists
exclusively of epoxy polymer C.2.1 (i.e. the size C.2 is free from
other polymers according to component C.2.2).
[0071] The epoxy polymer according to C.2.1 can be an epoxy resin,
an epoxy resin ester or an epoxy resin polyurethane, for
example.
[0072] In a preferred embodiment, the epoxy polymer according to
component C.2.1 is an epoxy resin comprising:
[0073] C.2.1.1 epichlorohydrin and
[0074] C.2.1.2 a preferably aromatic alcohol, which has at least
two hydroxyl groups.
[0075] Component C.2.1.2 is preferably a phenolic resin, for
example a novolak, or a compound of formula (I). Component C.2.1.2
is particularly preferably bisphenol A.
[0076] Component C.2.2 is preferably at least one polymer selected
from the group consisting of polyurethanes, polyolefins,
acrylate-containing polymers, styrene-containing polymers and
polyamides.
[0077] Component C.3 is preferably a silane. In a preferred
embodiment, the silane possesses a functional group selected from
the group of the amino group, epoxy group, carboxylic acid group,
vinyl group and mercapto group for binding to the polymer of the
size, as well as one to three, preferably three alkoxy groups for
binding to the glass fiber. For example and preferably, at least
one silane selected from the group consisting of
vinyltrichlorosilane, vinyltriethoxysilane, vinyltrimethoxysilane,
.gamma.-methacryloxypropyltrimethoxysilane,
.beta.-(3,4-epoxycyclohexyl)ethyltrimethoxysilane,
.gamma.-glycidoxypropyltrimethoxysilane,
N-.beta.-(aminoethyl)-.gamma.-aminopropyltrimethoxysilane,
.gamma.-aminopropyltriethoxysilane,
N-phenyl-.gamma.-aminopropyltrimethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane and
.gamma.-chloropropyltrimethoxysilane is used as component C.3.
Sized glass fibers which contain the component C.3 typically
exhibit better adhesion of the size to the glass fiber.
Component D
[0078] Component D comprises one or more graft polymers of [0079]
D.1 5 to 70 wt. %, preferably 10 to 60 wt. %, especially 20 to 50
wt. % of at least one vinyl monomer on [0080] D.2 30 to 95 wt. %,
preferably 40 to 90 wt. %, especially 50 to 80 wt. % of one or more
backbones with glass transition temperatures of <10.degree. C.,
preferably <0.degree. C., particularly preferably
<-20.degree. C.
[0081] Monomers D.1 are preferably mixtures of [0082] D.1.1 50 to
99 parts by weight vinyl aromatics and/or ring-substituted vinyl
aromatics (such as styrene, .alpha.-methylstyrene, p-methylstyrene,
p-chlorostyrene) and/or (C.sub.1-C.sub.8) alkyl methacrylates, such
as methyl methacrylate, ethyl methacrylate, and [0083] D.1.2 1 to
40 parts by weight of vinyl cyanides (unsaturated nitriles such as
acrylonitrile and methacrylonitrile) and/or (C.sub.1-C.sub.8) alkyl
(meth)acrylates, such as methyl methacrylate, n-butyl acrylate,
t-butyl acrylate, and/or derivatives (such as anhydrides and
imides) of unsaturated carboxylic acids, for example maleic
anhydride and N-phenylmaleimide.
[0084] Preferred monomers D.1.1 are selected from at least one of
the monomers styrene, .alpha.-methylstyrene and methyl
methacrylate; preferred monomers D.1.2 are selected from at least
one of the monomers acrylonitrile, maleic anhydride and methyl
methacrylate. Particularly preferred monomer combinations are D.1.1
styrene and D.1.2 acrylonitrile or D.1.1 and D.1.2 methyl
methacrylate.
[0085] The backbones D.2 suitable for the graft polymers D are, in
a preferred embodiment, saturated, i.e. substantially free from
double bonds. D.2 is particularly preferably at least one rubber
selected from the group consisting of acrylate rubbers, silicone
rubbers and silicone-acrylate composite rubbers. Most preferably,
D.2 is at least one rubber selected from the group consisting of
silicone rubbers and silicone-acrylate composite rubbers.
[0086] Suitable acrylate rubbers according to D.2 include
preferably polymers of alkyl acrylates, optionally with up to 40
wt. %, based on D.2, of other polymerisable, ethylenically
unsaturated monomers. The preferred polymerisable acrylates include
C.sub.1 to C.sub.8 alkyl esters, for example methyl, ethyl, butyl,
n-octyl and 2-ethylhexyl esters; haloalkyl esters, preferably
halo-C.sub.1-C.sub.8-alkyl esters, such as chloroethyl acrylate, as
well as mixtures of these monomers.
[0087] For crosslinking purposes, monomers with more than one
polymerizable double bond can be copolymerized. Preferred examples
of crosslinking monomers include esters of unsaturated
monocarboxylic acids with 3 to 8 C atoms and unsaturated monohydric
alcohols with 3 to 12 C atoms, or saturated polyols with 2 to 4 OH
groups and 2 to 20 C atoms, such as ethylene glycol dimethacrylate,
allyl methacrylate; polyunsaturated heterocyclic compounds, such as
trivinyl and triallyl cyanurate; polyfunctional vinyl compounds,
such as di- and trivinyl benzenes; but also triallyl phosphate and
diallyl phthalate. Preferred crosslinking monomers are allyl
methacrylate, ethylene glycol dimethacrylate, diallyl phthalate and
heterocyclic compounds having at least three ethylenically
unsaturated groups. Particularly preferred crosslinking monomers
are the cyclic monomers triallyl cyanurate, triallyl isocyanurate,
triacryloylhexahydro-s-triazine, triallyl benzenes. The quantity of
the crosslinked monomers is preferably 0.02 to 5, especially 0.05
to 2 wt. %, based on the backbone D.2. In the case of cyclic
crosslinking monomers with at least three ethylenically unsaturated
groups, it is generally advantageous to limit the quantity to less
than 1 wt. % of the backbone D.2.
[0088] Preferred "other" polymerizable, ethylenically unsaturated
monomers which may optionally be used in addition to the acrylates
for the production of the backbone D.2 are e.g. acrylonitrile,
styrene, .alpha.-methylstyrene, acrylamides,
vinyl-C.sub.1-C.sub.6-alkyl ethers and methyl methacrylate.
[0089] Other suitable backbones according to D.2 include silicone
rubbers with graft-active points, as described in DE-OS 3 704 657,
DE-OS 3 704 655, DE-OS 3 631 540 and DE-OS 3 631 539.
[0090] The graft copolymers D can be produced for example by
free-radical polymerization, preferably by emulsion
polymerization.
[0091] The backbone D.2 generally has an average particle size
(d.sub.50 value) of 0.05 to 1 .mu.m, preferably 0.07 to 0.5 .mu.m,
particularly preferably 0.1 to 0.4 .mu.m. The average particle size
d.sub.50 is the diameter having 50 wt. % of the particles lying
above it and 50 wt. % below it. It can be determined by means of
ultracentrifuge measurement (W. Scholtan, H. Lange, Kolloid, Z. und
Z. Polymere 250 (1972), 782-1796).
[0092] The gel content of the backbone D.2 in graft polymers
produced by emulsion polymerization is preferably at least 30 wt.
%, particularly preferably at least 40 wt. %, especially at least
50 wt. % (measured in toluene). The gel content is determined at
25.degree. C. in a suitable solvent as the portion that is
insoluble in these solvents (M. Hoffmann, H. Kromer, R. Kuhn,
Polymeranalytik I and II, Georg Thieme-Verlag, Stuttgart 1977).
[0093] Since it is known that, during the graft reaction, the graft
monomers are not necessarily grafted on to the backbone completely,
graft polymers D according to the invention also include those
products obtainable by (co)polymerization of the graft monomers in
the presence of the backbone and jointly formed during the work-up.
These products can therefore also contain free (co)polymer of the
graft monomers, i.e. they are not chemically bonded to the
rubber.
E) Other Components
[0094] The composition may contain other optional additives as
component E, with polymer additives such as flame retardants (e.g.
organic phosphorus or halogen compounds, especially bisphenol
A-based oligophosphate), anti-drip agents (e.g. compounds of the
classes of substances of the fluorinated polyolefins, the silicones
and aramid fibers), lubricants and mould release agents, e.g.
pentaerythritol tetrastearate, nucleating agents, antistatic
agents, stabilisers, fillers and reinforcing materials other than
component C (e.g. carbon fibers, talc, mica, kaolin, CaCO.sub.3),
as well as dyes and pigments (e.g. titanium dioxide or iron oxide),
being particularly suitable.
Production of the Molding Compositions and Shaped Articles
[0095] The thermoplastic molding compositions according to the
invention can be produced, for example, by mixing the respective
components in a known manner and melt-compounding and
melt-extruding them at temperatures of 200.degree. C. to
320.degree. C., preferably at 240 to 300.degree. C., in
conventional equipment such as internal mixers, extruders and twin
screw extruders.
[0096] The mixing of the individual components can take place in a
known manner, either successively or simultaneously, and either at
about 20.degree. C. (room temperature) or at a higher
temperature.
[0097] In a preferred embodiment, the production of the
compositions according to the invention takes place in a twin screw
extruder, the components A, B, D and E first being melted and mixed
and the glass fibers C then being introduced into the melt mixture
via a subsidiary extruder and dispersed therein.
[0098] The invention thus also provides a process for the
production of the compositions according to the invention.
[0099] The molding compositions according to the invention can be
used for the production of shaped articles of all kinds. These can
be produced, for example, by injection molding, extrusion and blow
molding processes. Another form of processing is the production of
shaped articles by thermoforming from previously produced sheets or
films.
[0100] Examples of these shaped articles are films, profiles, all
kinds of housing parts, e.g. for domestic appliances such as juice
presses, coffee machines, mixers; for office equipment such as
monitors, flat screens, notebooks, printers, copiers; sheets,
pipes, electrical installation ducts, windows, doors and other
profiles for the construction sector (interior finishing and
exterior applications) as well as electrical and electronic parts
such as switches, plugs and sockets and components for utility
vehicles, particularly for the car sector. The compositions
according to the invention are also suitable for the production of
the following shaped articles or moulded parts: interior fittings
for rail vehicles, ships, aircraft, buses and other motor vehicles,
body parts for motor vehicles, housings for electrical appliances
containing small transformers, housings for equipment for data
processing and transfer, housings and claddings for medical
equipment, massage equipment and housings therefor, toy vehicles
for children, flat wall elements, housings for safety devices,
thermally insulated transport containers, moldings for sanitary and
bath equipment, covering grid plates for ventilation openings and
housings for garden equipment.
EXAMPLES
[0101] Component A:
Linear polycarbonate based on bisphenol A with a weight-average
molecular weight M.sub.w of 28 000 g/mole (determined by GPC).
[0102] Component B-1:
SAN copolymer with an acrylonitrile content of 23 wt. % and a
weight-average molecular weight of about 130 000 g/mole.
[0103] Component B-2:
ABS polymer with an acrylonitrile content:butadiene:styrene ratio
of 20:28:52 wt. %, produced by emulsion polymerization.
[0104] Component C-1:
Chopped glass strands with an average diameter of 13 .mu.m and a
size made of epoxy resin produced from epichlorohydrin and
bisphenol A. The carbon content of component C-1 is 0.6 wt. %.
[0105] Component C-2:
Chopped glass strands with an average diameter of 13 .mu.m and a
polyurethane size. The carbon content of component C-1 is 0.4 wt.
%.
[0106] Component D:
Metablen.RTM. SRK200 (Mitsubishi Rayon, Japan):
styrene-acrylonitrile grafted acrylate-silicone composite rubber,
produced by emulsion polymerization.
[0107] Component E-1: Pentaerythritol tetrastearate
[0108] Component E-2: Phosphite stabiliser
Production and Testing of the Molding Compositions According to the
Invention
[0109] The components are mixed in a ZSK-25 twin screw extruder
from Werner & Pfleiderer at a melt temperature of 260.degree.
C. The moldings are produced at melt temperatures of 260.degree. C.
and 300.degree. C. and a mould temperature of 80.degree. C. using
an injection molding machine of the Arburg 270 E type.
[0110] The melt viscosity measured at 260.degree. C. and a shear
rate of 1000 s.sup.-1 in accordance with ISO 11443 serves as a
measure of the melt flowability.
[0111] The impact resistance is determined at 23.degree. C. in
accordance with ISO 180-1U on specimens measuring 80 mm.times.10
mm.times.4 mm. The specimens were injection moulded at melt
temperatures of 260.degree. C. and 300.degree. C. The change in
impact resistance a.sub.k on increasing the processing temperature
serves as a measure of the processing stability of the composition
and is calculated as follows:
Processing stability = a K 260 .degree. C . - a K 300 .degree. C .
a K 260 .degree. C . * 100 % ##EQU00001##
[0112] The modulus of elasticity is determined on test bars
injection moulded at 260.degree. C., in accordance with ISO
527.
[0113] The stress cracking (ES C) resistance in rapeseed oil at
room temperature serves as a measure of the chemical resistance.
The time taken to fracture failure induced by stress cracking is
determined on a specimen measuring 80 mm.times.10 mm.times.4 mm,
injection moulded at a melt temperature of 260.degree. C., which is
subjected to an outer fiber strain of 2.4% using a strain jig and
completely immersed in the medium. The measurement is performed on
the basis of ISO 4599.
[0114] The reduction in impact resistance determined at 23.degree.
C. in accordance with ISO 180-1U on specimens measuring 80
mm.times.10 mm.times.4 mm, injection moulded at 260.degree. C.,
when stored in hot air at 120.degree. C. for 1500 h serves as a
measure of heat aging resistance.
[0115] The change in colour (change in grey scale) of specimens
measuring 60 mm.times.40 mm.times.2 mm, injection moulded at
260.degree. C., subjected to hot light aging in accordance with VW
standard PV 1303 over 6 illumination cycles, serves as a measure of
UV light resistance.
TABLE-US-00001 TABLE 1 Molding compositions and their properties 1
2 3 5 6 7 9 (cp.) (cp.) (cp.) 4 (cp.) (cp.) (cp.) 8 (cp.) 10 11 12
Components [parts by wt.] A PC 60.64 60.64 60.64 60.64 49.75 49.75
49.75 49.75 61.81 61.94 49.46 43.52 B-1 SAN -- 28.83 -- 28.83 --
29.85 -- 29.85 21.93 26.97 29.67 25.72 B-2 ABS 28.83 -- 28.83 --
29.85 -- 29.85 -- -- -- -- -- C-1 GF (epoxy-sized) -- -- 9.94 9.94
-- -- 19.90 19.90 9.97 9.99 19.78 29.67 C-2 GF (PU-sized) 9.94 9.94
-- -- 19.90 19.90 -- -- -- -- -- -- D Metablen SRK200 -- -- -- --
-- -- -- -- 5.98 0.50 0.49 0.49 E-1 PETS 0.50 0.50 0.50 0.50 0.40
0.40 0.40 0.40 0.20 0.50 0.49 0.49 E-2 Irganox B900 0.10 0.10 0.10
0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Properties Impact
resistance a.sub.K.sup.260.degree. C. 30 25 43 39 23 27 n.t. 40 39
37 40 38 [kJ/m.sup.2] Impact resistance a.sub.K.sup.300.degree. C.
33 17 n.t. 35 n.t. n.t. n.t. n.t. 39 37 37 38 [kJ/m.sup.2]
Processing stability [%] -10.0 32.0 n.t. 10.3 n.t. n.t. n.t. n.t.
0.0 0.0 7.5 0.0 Melt viscosity [Pas] 315 193 329 229 333 187 356
202 247 212 198 233 Modulus of elasticity [MPa] 3736 5147 3961 5070
5729 7000 5994 7488 4623 5189 7604 10178 ESC-time to fracture [h]
1.5 0.1 n.t. 21 0.5 0.02 n.t. 19 2.5 11 8 0.07 Change in toughness
with heat n.t. n.t. n.t. n.t. -41 n.t. n.t. +4 n.t. n.t. n.t. n.t.
aging (1500 h at 120.degree. C.) [%] Colour change with hot light
n.t. n.t. n.t. V -1.5 n.t. V +/-0 n.t. n.t. n.t. n.t. aging (change
in grey scale in 6 cycles) n.t. = not tested
[0116] It can be seen from Table 1 that those compositions
containing butadiene rubber-modified styrene resin (comparative
examples 1, 3, 5, 7 and 9) or SAN in combination with a relatively
large amount of a rubber-modified graft polymer (comparative
example 9) exhibit inadequate flowability and an inadequate modulus
of elasticity compared with examples according to the invention
having the same glass fiber content (examples 4, 8, 10-12).
Moreover, when butadiene rubber-modified styrene resins are used
(comparative examples 5), the heat aging and light resistance are
also unsatisfactory. The compositions that do not contain glass
fibers having an epoxy polymer-based size (comparative examples 1,
2, 5 and 6) are distinguished by poorer toughness compared with
those comparable compositions with glass fibers having an epoxy
polymer-based size. Although the rubber-free compositions
containing glass fibers without an epoxy polymer-based size
(comparative examples 2 and 6) do exhibit good flowability, they
have very poor chemical resistance and processing stability. A good
combination of flowability, rigidity, chemical resistance,
toughness, processing stability and aging resistance under the
effects of light and heat is only achieved in the compositions
according to the invention (examples 4, 8, 10-12).
[0117] 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 may
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.
[0118] Additional advantages, features and modifications will
readily occur to those skilled in the art. Therefore, the invention
in its broader aspects is not limited to the specific details, and
representative devices, shown and described herein. Accordingly,
various modifications may be made without departing from the spirit
or scope of the general inventive concept as defined by the
appended claims and their equivalents.
[0119] All documents referred to herein are specifically
incorporated herein by reference in their entireties.
[0120] As used herein and in the following claims, articles such as
"the", "a" and "an" can connote the singular or plural.
* * * * *