U.S. patent application number 17/512806 was filed with the patent office on 2022-02-17 for polyarylene ether sulfone comprising naphthalic acid anhydride endgroups.
This patent application is currently assigned to BASF SE. The applicant listed for this patent is BASF SE. Invention is credited to Gad Kory, Christian Maletzko, Helmut Reichelt, Stefan Schwiegk, Martin WEBER.
Application Number | 20220049096 17/512806 |
Document ID | / |
Family ID | 1000005940640 |
Filed Date | 2022-02-17 |
United States Patent
Application |
20220049096 |
Kind Code |
A1 |
WEBER; Martin ; et
al. |
February 17, 2022 |
POLYARYLENE ETHER SULFONE COMPRISING NAPHTHALIC ACID ANHYDRIDE
ENDGROUPS
Abstract
A polyarylene ether sulfone contains endgroups of formula (I),
##STR00001## A molding composition contains the polyarylene ether
sulfone; and a fiber, film, or shaped article can be produced using
the molding composition.
Inventors: |
WEBER; Martin;
(Ludwigshafen, DE) ; Reichelt; Helmut;
(Ludwigshafen, DE) ; Schwiegk; Stefan;
(Ludwigshafen, DE) ; Kory; Gad; (Gaiberg, DE)
; Maletzko; Christian; (Ludwigshafen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BASF SE |
Ludwigshafen am Rhein |
|
DE |
|
|
Assignee: |
BASF SE
Ludwigshafen am Rhein
DE
|
Family ID: |
1000005940640 |
Appl. No.: |
17/512806 |
Filed: |
October 28, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16482582 |
Jul 31, 2019 |
11193020 |
|
|
PCT/EP2018/051160 |
Jan 18, 2018 |
|
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17512806 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08L 2205/025 20130101;
C08L 77/06 20130101; C08L 81/06 20130101; C08L 2203/16 20130101;
C08L 2205/035 20130101; C08J 5/18 20130101; C08G 75/23 20130101;
C08J 2477/06 20130101; C08J 2377/06 20130101; C08L 2205/03
20130101; C08J 2381/06 20130101; C08J 2481/06 20130101; C08L
2203/12 20130101 |
International
Class: |
C08L 81/06 20060101
C08L081/06; C08G 75/23 20060101 C08G075/23; C08J 5/18 20060101
C08J005/18; C08L 77/06 20060101 C08L077/06 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 1, 2017 |
EP |
17154116.2 |
Claims
1-16. (canceled)
17: A molding composition, comprising: from 5 to 95% by weight of
at least one polyarylene ether sulfone comprising endgroups of
formula (I), ##STR00010## from 5 to 95% by weight of at least one
polyamide, and optionally, at least one further component, wherein
a total proportion of all components by weight is 100%, based on
the molding composition.
18: The molding composition according to claim 17, comprising: from
30 to 75% by weight of the at least one polyarylene ether sulfone,
and from 25 to 70% by weight of the at least one polyamide.
19: The molding composition according to claim 17, wherein the at
least one polyamide is selected from the group consisting of PA 9T,
PA 9T-co-8.1T, PA 6T6I, PA 6T66, PA 66T, and a mixture thereof.
20: The molding composition according to claim 17, wherein the at
least one further component is at least one polyarylene ether
sulfone having no endgroups of formula (I), wherein the molding
composition comprises 10 to 70% by weight of the at least one
polyarylene ether sulfone having no endgroups of formula (I).
21: The molding composition according to claim 17, wherein the at
least one further component is at least one fibrous or particulate
filler, and wherein the molding composition comprises 10 to 62.5%
by weight of the at least one fibrous or particulate filler.
22: A fiber, film, or shaped article, comprising the molding
composition according to claim 17.
23: The molding composition according to claim 17, wherein the at
least one polyarylene ether sulfone comprises at least 15% of the
endgroups of formula (I).
24: The molding composition according to claim 17, wherein the at
least one polyarylene ether sulfone comprises from 25% to 90% of
the endgroups of formula (I).
25: The molding composition according to claim 17, wherein the at
least one polyarylene ether sulfone further comprises repeat units
of general formula (II) ##STR00011## wherein t and q are
independently 0, 1, 2, or 3; Q, T, and Y are independently in each
case a chemical bond or a group selected from the group consisting
of --O--, --S--, --SO.sub.2--, S.dbd.O, C.dbd.O, --N.dbd.N--, and
--CRaRb-, wherein Ra and Rb are independently in each case a
hydrogen atom, a C.sub.1-C.sub.12-alkyl group, a
C.sub.1-C.sub.12-alkoxy group, or a C.sub.6-C.sub.18-aryl group,
and wherein at least one of Q, T, and Y is --SO.sub.2--; and Ar and
Ar.sup.1 are independently an arylene group having from 6 to 18
carbon atoms.
26: The molding composition according to claim 17, wherein the at
least one polyarylene ether sulfone comprises at least one of the
following repeat units: ##STR00012##
27: A molding composition, comprising at least one polyarylene
ether sulfone comprising endgroups of formula (I), ##STR00013##
wherein the molding composition comprises at least one polyamide
selected from the group consisting of PA 9T, PA 9T-co-8.1T, PA
6T6I, PA 6T66, PA 66T, and a mixture thereof.
28: A molding composition, comprising at least one polyarylene
ether sulfone comprising endgroups of formula (I), ##STR00014##
wherein the molding composition comprises from 10 to 62.5% by
weight of at least one fibrous or particulate filler, based on a
total weight of the molding composition.
Description
[0001] The present invention relates to polyarylene ether sulfones
having anhydride endgroups.
[0002] Polyarylene ethers are classified as high-performance
thermoplastics. Polyarylene ethers may have--depending on how they
are produced--for instance hydroxy, halogen, amino, epoxy or
anhydride endgroups. EP 840 758 A discloses polyarlyene ethers with
phthalic acid anhydride endgroups. These are obtained by reacting a
hydroxy endgroup containing polyarylene ether with halogen
substituted phthalic acid anhydride in the presence of potassium
fluoride. EP 840 758 A further discloses that the so obtained
polyarylene ethers are useful for molding compositions comprising
polyamide.
[0003] The problem addressed by the present disclosure is to
present new polyarylene ether sulfones as well as compositions
comprising said polyarylene ether sulfones. In addition, the
present disclosure was to point to blends or alloys of said
polyarylene ether sulfones with other polymers. Moreover, the
polyarlene ether sulfones should support the manufacture of films,
fibers and shaped articles based on mixtures comprising polyarylene
ether sulfones and polyamide which are high temperature resistant,
having good chemical resistance as well as a good current tracking
index (CTI). Further, a process for the manufacture of said new
polyarylene ether sulfones should be provided.
[0004] Hereinunder a polyarylene ether sulfone is disclosed which
comprises endgroups of formula I
##STR00002##
[0005] Further, a process for the manufacture of a polyarylene
ether sulfone comprising endgroups of formula I is disclosed which
comprises reacting a polyarylene ether sulfone comprising phenolate
endgroups with 4-chloro-1,8-naphthalic acid anhydride. In addition
a process is encompassed wherein the polyarylene sulfone comprising
endgroups of formula I is obtained comprising reacting polyarylene
ether sulfone forming monomers with 4-chloro-1,8-naththialic acid
anhydride. The use of said, respectively the so obtained,
polyarylene ether sulfone for the manufacture of a composition is
also disclosed herein. The present disclosure also pertains to a
composition comprising said, respectively the so obtained,
polyarylene ether sulfone. In addition, this disclosure encompasses
the use of the composition for the manufacture of a fiber, film or
shaped article as well as a fiber, film or shaped article produced
using the composition.
[0006] In the following "at least one" may in general mean one or
two or more, such as three or four or five or more, wherein more
may mean a plurality or an uncountable. For instance, it may mean
one or a mixture of two or more. If used in connection with
chemical compounds "at least one" is meant in the sense that one or
two or more chemical compounds differing in their chemical
constitution, that is chemical nature, are described.
[0007] In the following "polymer" may mean homopolymer or copolymer
or a mixture thereof. The person skilled in the art appreciates
that any polymer, may it be a homopolymer or a copolymer by nature
typically is a mixture of polymeric individuals differing in their
constitution such as chain length, degree of branching or nature of
endgroups. Thus in the following "at least one" as prefix to a
polymer means that different types of polymers may be encompassed
whereby each type may have the difference in constitution addressed
above.
[0008] For the purposes of the present invention, a rubber is
generally either a crosslinkable polymer or a flexible, low
Tg-polymer having elastomeric properties at room temperature.
[0009] In the following a polyarylether comprising endgroups of
formula I may also be termed "PNA".
[0010] Polyarylene ether sulfones are a class of polymers known to
a person skilled in the art. In principle, a polyarylene ether
sulfone of any structure is encompassed by the present disclosure
provided that the polyarylene ether sulfone comprises endgroups of
formula I.
[0011] It may be preferred that the PNA is composed of units of the
general formula II
##STR00003##
where the definitions of the symbols t, q, Q, T, Y, Ar and Ar.sup.1
are as follows: [0012] t, q: Independently of one another 0, or 1,
or 2, or 3, [0013] Q, T, Y: independently of one another in each
case a chemical bond or group selected from --O--, --S--, --SO2-,
S.dbd.O, C.dbd.O, --N.dbd.N--, and --CRaRb-, where Ra and Rb
independently of one another are in each case a hydrogen atom or a
C1 to C12-alkyl, C1 to C12-alkoxy, C3 to C12-cycloalkyl, or C6 to
C18-aryl group, and where at least one of Q, T, and Y is --SO2-,
and [0014] Ar and Ar.sup.1: independently of one another an arylene
group having from 6 to 18 carbon atoms.
[0015] If, within the abovementioned preconditions, Q, T or Y is a
chemical bond, this then means that the adjacent group on the
left-hand side and the adjacent group on the right-hand side are
present with direct linkage to one another via a chemical bond.
[0016] However, it may be preferable that Q, T, and Y in formula II
are selected independently of one another from --O-- and --SO2-,
with the proviso that at least one of the group consisting of Q, T,
and Y is --SO2-.
[0017] If Q, T, or Y is --CRaRb-, Ra and Rb independently of one
another are in each case a hydrogen atom or a C1 to C12-alkyl, C1
to C12-alkoxy, or C6 to C18-aryl group.
[0018] It may be preferred that C1 to C12-alkyl comprises linear
and branched, saturated alkyl groups having from 1 to 12 carbon
atoms. The following moieties may be mentioned in particular: C1 to
C6-alkyl moiety, e.g. methyl, ethyl, n-propyl, isopropyl, n-butyl,
sec-butyl, 2- or 3-methylpentyl, and longer chain moieties, e.g.
unbranched heptyl, octyl, nonyl, decyl, undecyl, lauryl, and the
singly branched or multibranched analogs thereof.
[0019] Alkyl moieties that can be used in the abovementioned C1 to
C12-alkoxy groups are for instance the alkyl moieties defined above
having from 1 to 12 carbon atoms.
[0020] C3 to C12-cycloalkyl may in particular comprise C3 to C8
cycloalkyl, e.g. cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl,
cycloheptyl, cyclooctyl, cyclopropylmethyl, cyclopropylethyl,
cyclopropylpropyl, cyclobutylmethyl, cyclobutylethyl,
cyclopentylethyl, -propyl, -butyl, -pentyl, -hexyl,
cyclohexylmethyl, -dimethyl, and -trimethyl.
[0021] Ar and Ar1 are independently of one another a C6 to
C18-arylene group. It may be preferable that Ar derives from an
electron-rich aromatic substance that is very susceptible to
electrophilic attack, whereby it may be preferably hydroquinone,
resorcinol, dihydroxynaphthalene, in particular it may be
2,7-dihydroxynaphthalene, or 4,4'-bisphenol. Ar1 may preferably be
an unsubstituted C6- or C12-arylene group.
[0022] It may particularly be preferred that C6 to C18-arylene
groups Ar and Ar1 are phenylene groups, and independently of one
another e.g. 1,2-, 1,3-, and 1,4-phenylene, naphthylene groups,
e.g. 1,6-, 1.7-, 2,6-, or 2,7-naphthylene, or also the arylene
groups that derive from anthracene, from phenanthrene, or from
naphthacene.
[0023] It may be preferable that Ar and Ar are independently of one
another 1,4-phenylene, 1,3-phenylene, naphthylene, in particular
2,7-dihydroxynaphthylene, or 4,4'-bisphenylene.
[0024] It may be preferred that the PNA comprises at least one of
the following repeat units IIa to IIo:
##STR00004##
[0025] Other repeat units, in addition to the units IIa to IIo that
may preferably be present, are those in which one or more
1,4-phenylene units deriving from hydroquinone have been replaced
by 1,3-phenylene units deriving from resorcinol, or by naphthylene
units deriving from dihydroxynaphthalene.
[0026] Units of the general formula II that may be particularly
preferred are the units IIa, IIg, and/or IIk. It may also be
particularly preferable that the PNA is in essence composed of one
type of unit of the general formula II, whereby one type may in
particular be selected from IIa, IIg, and IIk.
[0027] The PNA may particularly preferably be composed of repeat
units where Ar is 1,4-phenylene, t is 1, q is 0, T is a chemical
bond, and Y is SO2. This polyarylene ether sulfone is also termed
polyphenylene sulfone (PPSU-NA) (formula IIg).
[0028] The PNA may particularly preferably be composed of repeat
units where Ar is 1,4-phenylene, t is 1, q is 0, T is C(CH3)2, and
Y is SO2. This polyarylene ether sulfone is also termed polysulfone
(PSU-NA) (formula IIa).
[0029] The PNA may particularly preferably be composed of repeat
units where Ar is 1,4-phenylene, t is 1, q is 0, T and Y are SO2.
This polyarylene ether sulfone is also termed polyether sulfone
(PESU-NA) (formula IIk).
[0030] For the purposes of the present disclosure, abbreviations
such as PPSU, PESU, and PSU are in accordance with DIN EN ISO
1043-1:2001.
[0031] The polyarylene ether sulfone comprises end groups of
formula I
##STR00005##
[0032] It may be possible that the PNA is branched and has more
than one end group per individual polymer chain. Typically, the PNA
is linear and has two end groups per individual polymer chain.
[0033] The amount of end groups of formula I can be small or very
small, that is only few of the end groups are endgroups of formula
I. It is possible that 100% or almost 100% end groups, that is all
or almost all end groups, are end groups of formula I. It may be
preferred that the polyarylether sulfone comprises at least 10%
endgroups of formula I, or in other words that at least ten of 100
end groups are end groups of formula I. In the case the PNA is
linear mathematically at least every fifth individual polymer chain
has one end group of formula I or that at least every tenth
individual polymer chain has two end groups of formula I. The
person skilled in the art appreciates that in practice other
distributions fulfill the requirement. It may be preferred that at
least 25%, that is at least 25 of 100 end groups are end groups of
formula I. Any percentage of end groups between 10% and 100% may be
end groups of formula I, such as 30%, 40%, 50% 60%, 70%, 80% or 90%
or any uneven percentage in between 10% and 100%. It may be
preferred that from 10% to 90% end groups are end groups of formula
I. It may be more preferred that from 15 to 90%, such as 25% to 80%
end groups are end groups of formula I, for instance from 30% to
70%.
[0034] The nature of the end groups which are not end groups of
formula I is not particularly limited. Generally, it may depend on
if reactive or non-reactive end groups are desired in addition to
the end groups of formula I. Reactive end groups may for instance
be preferred if it is intended to polymerize the PNA with at least
one further monomer or polymer to yield a copolymer or a polymer
network. Possible end groups which are not end groups of formula I
are phenolic OH end groups or phenolate end groups, phenolic alkoxy
end groups, among which --OCH.sub.3 end groups may be preferred,
amino end groups, among which --NH2 may be preferred, halogen end
groups, which can in particular be --F or --Cl. Cl may be most
preferred among the halogen end groups. It is also possible that
the end groups which are not end groups of formula I are phenolic
anhydride end groups. The end groups which are not end groups of
formula I can be of one type or can be different from each other.
Generally it may be preferred that the end groups other than those
of formula I are Cl--, OH-- and OCH.sub.3.
[0035] For example the PNA listed in Table 1 may be particularly
preferred
TABLE-US-00001 TABLE 1 Polyarylene ether sulfone % endgroups
formula I Further endgroups PPSU-NA 15 to 30 Cl, OH PPSU-NA 15 to
30 OH, OCH.sub.3 and Cl PPSU-NA 40 to 80 OH, Cl PPSU-NA 40 to 80
OH, OCH.sub.3 and Cl PESU-NA 25 to 50 Cl, OH PESU-NA 25 to 50 OH,
Cl, OCH.sub.3 PESU-NA 40 to 90 Cl, OH PESU-NA 40 to 90 OH, Cl,
OCH.sub.3 PSU-NA 20 to 40 CL, OH PSU-NA 20 to 40 OH, Cl, OCH.sub.3
PSU-NA 30 to 75 Cl, OH PSU-NA 30 to 75 OH, Cl, OCH.sub.3
[0036] The weight-average molar mass Mw of the PNA may preferably
be from 10 000 to 150 000 g/mol, in particular it may be from 15000
to 120 000 g/mol and it may be particularly preferably from 18000
to 100 000 g/mol, determined by means of gel permeation
chromatography in dimethylacetamide as solvent against
narrowly-distributed polymethyl methacrylate as standard
(calibration between 800 to 1820000 g/mol), using 4 columns
(pre-column, 3 separation columns based on polyester copolymers)
operated at 80.degree. C. The flow rate was set to 1 ml/min,
injection volume was 100 .mu.l. Detection was done using an
RI-detector.
[0037] The molecular weight distribution (MWD) of the polymers is
2.0 to 6, preferably between 2.2 and 4.5.
[0038] The apparent melt viscosity at 350.degree. C./1150 s-1 of
the PNA may preferably be from 50 to 500 Pas, with a possible
preference from 150 to 275 Pas. Flowability can be assessed on the
basis of melt viscosity. Melt viscosity is determined by means of a
capillary rheometer. Apparent viscosity at 350.degree. C.
determined here as a function of shear rate in a capillary
viscometer (Gottfert Rheograph 2003 capillary viscometer) using a
circular capillary of length 30 mm, radius 0.5 mm, an inlet angle
of 180.degree. for the nozzle, a diameter of 12 mm for the melt
reservoir vessel, and a preheating time of 5 minutes. The values
stated are determined at 1150 s.sup.-1.
[0039] The polyarylene ether sulfone comprising endgroups of
formula I can be prepared by a process comprising reacting a
polyarylene ether sulfone comprising phenolate end groups with
4-chloro-1,8-naphthalic acid anhydride. The amount of the end
groups being phenolate end groups generally will depend on the
desired amount of end groups of formula I. Thus it can be small or
very small, that is only few of the end groups are phenolate end
groups. It is possible that 100% or almost 100% end groups, that is
all or almost all end groups, are phenolate end groups.
Consequently, it may be preferred that at least 25%, that is at
least 25 of 100 end groups are phenolate end groups. Any percentage
of end groups between 10% and 100% may be phenolate end groups,
such as 30%, 40%, 50% 60%, 70%, 80% or 90% or any uneven percentage
in between 10% and 100%. It may be preferred that from 10% to 90%
end groups are phenolate end groups. It may be more preferred that
from 25% to 90% phenolate end groups are end groups, for instance
from 30% to 70%. The content of OH/O.sup.- endgroups can be
determined by potentiometric titration of the polymer after
neutralization and precipitation using NH.sub.4OH in DMF as
solvent.
[0040] The polyarylene ether sulfone comprising phenolate end
groups may be prepared by any suitable method. Such methods are
either known to the person skilled in the art or are accessible to
him by application of his general knowledge. Production processes
that lead to a polyarylene ether sulfone are described by way of
example in Herman F. Mark, "Encyclopedia of Polymer Science and
Technology", third edition, volume 4, 2003, chapter "Polysulfones"
pages 2 to 8, and also in Hans R. Kricheldorf, "Aromatic
Polyethers" in: Handbook of Polymer Synthesis, second edition,
2005, pages 427 to 443. More details regarding the synthesis of
OH-terminated polyarylene ether sulfones are for instance given in
R. Viswanathan, B. C. Johnson, J. E. McGrath, Polymer 25 (1984)
1827.
[0041] Particular preference may be given to the reaction between
at least one aromatic compound having two halogen substituents and
at least one aromatic compound having two functional groups
reactive toward abovementioned halogen substituents. Said at least
one aromatic compound may be monomeric or oligomeric or polymeric.
For example, in order to obtain block copolymers, it may be
possible to react at least one polymeric aromatic compound with at
least one monomeric aromatic compound. Typically, it may be
preferred to carry out the reaction in at least one aprotic polar
solvent, such as dimethylsulfone, dimethylsulfoxide,
diphenylsulfone, dimethylacetamide or N-methylpyrrolidone or any
combination thereof. It may be preferred to use one solvent. It may
be most preferred to carry out the reaction in N-methylpyrrolidone.
While the reaction can be carried out using a co-solvent which
forms an azeotrope with water for instance toluene or chlorobenzene
it is typically preferred not to employ such a co-solvent. It may
also be possible to carry out the polymerization in absence of a
solvent. Generally, the reaction can be carried out in the presence
of at least one base. It may be preferred that it is carried out in
the presence of at least one anhydrous alkali metal carbonate,
where one may be preferred, in particular sodium carbonate,
potassium carbonate, calcium carbonate, or a mixture thereof, very
particularly preferably potassium carbonate. One particularly
suitable combination may be N-methylpyrrolidone as solvent and
potassium carbonate as base. To accelerate the reaction or achieve
high conversion, it can be advantageous to use potassium carbonate
of a particle size (volume average, measured by light scattering)
below 100 .mu.m, more preferably below 50 .mu.m.
[0042] The molecular weight of the polyarylene ether sulfone
comprising phenoloate end groups can be adjusted using a defined
off-set of the stoichiometric ratio between the OH- and the
Cl-monomer, as described in A. Noshay, M. Matzner, C. N. Merriam,
J. Polym. Sci. A-1 9 (1971) 3147. Usually an excess OH-monomer is
applied to have phenolate-endgroups for the subsequent conversion.
This usually leads to polyarylene ether sulfones having 1,8 to 2
phenolate-endgroups per chain if a high conversion is obtained
(>95%). Another way to control the molecular weight of the
phenolate-terminated polyarylene ether sulfone is possible by
monitoring the viscosity increase during the reaction. This
approach can be used if polyarylene ether sulfones of a dedicated
Mn with less than 2 phenolate endgroups are prepared.
[0043] The reaction between the polyarylene ether sulfone
comprising phenolate end groups with 4-chloro-1,8-naphthalic acid
anhydride may preferably also be carried out in the presence of at
least one aprotic solvent, whereby the above-mentioned are
typically preferred. Generally, this reaction may be carried out in
the presence of at least one base, whereby the above-mentioned
bases are typically preferred. One particularly suitable
combination may be N-methylpyrrolidone as solvent and potassium
carbonate as base.
[0044] It may be more preferred that the polyarylene ether sulfone
comprising end groups of formula I is obtained in a one-pot
synthesis from the respective polyarylene ether sulfone forming
monomers. Thereby it may be preferred that a phenolate is formed
first via reacting an excess of at least one monomer having hydroxy
groups with at least one base in the presence of at least one
solvent prior to contacting the obtained mixture with at least one
monomer having halogen groups. It may be preferred that the at
least one monomer having halogen groups is added to said mixture.
Thereby it may be preferred reacting a monomer having two hydroxy
groups with a monomer having two halogen groups, whereby two
chlorine groups may be preferred.
[0045] Said at least one base can typically be a hydroxide,
carbonate or bicarbonate. Thus it may be a mixture of at least one
hydroxide and at least one carbonate or a mixture of at least one
bicarbonate with at least one bicarbonate. Thereby at least one
anhydrous alkali metal carbonate may be preferred. It may be
preferred to use one base. It may be preferred that the one base is
one alkali metal carbonate. In particular sodium carbonate,
potassium carbonate, calcium carbonate, or a mixture thereof may be
preferred, very particularly it may be preferred that potassium
carbonate is used as the base. It may be advantageous to use an
excess of base relative to the monomeric hydroxy groups. Said
excess may for instance be from 1 to 25 mol %.
[0046] It may be preferred that the reaction is carried out in at
least one aprotic polar solvent, where one may be preferred.
Typically, it is preferred to carry out the reaction in at least
one aprotic polar solvent, such as dimethylsulfone,
dimethylsulfoxide, diphenylsulfone, dimethylacetamide or
N-methylpyrrolidone or any combination thereof, whereby
N-methylpyrrolidone may be the preferred one. To separate the water
released during the reaction either an azeotrope-forming co-solvent
like toluene or chlorobenzene may be used. Typically, it may be
preferred not to employ such azeotrope-forming co-solvent.
Separation of the water together with the solvent during the
heating process may generally be preferred. Loss of solvent can be
accounted for by for instance adding solvent during the
reaction.
[0047] One particularly suitable combination may be
N-methylpyrrolidone as solvent and potassium carbonate as base.
Thereby it may be preferred to use an excess of 1 to 25 mol % of
potassium carbonate based on the monomeric hydroxy groups.
[0048] While the person skilled in the art may adapt the reaction
temperatures and times to the specific polyarylene ethers to be
produced reaction temperatures in the range of from 180 to
205.degree. C. may be applicable and temperatures from 185 to
195.degree. C. may be preferred. At the latter temperatures the
reaction may take from 3 to 12 hours, e.g. from 4 to 10 hours.
[0049] The reaction mixture is generally thereafter contacted with
4-chloro-1,8-naphthalic acid anhydride, whereby it may be preferred
that the 4-chloro-1,8-naphthalic acid anhydride is added to the
reaction mixture. It may be more preferred that the
4-chloro-1,8-naphthalic acid anhydride is added as a solution in at
least one solvent, N-methyl-pyrrolidone being typically preferred.
The temperature of the reaction mixture during contact, preferably
addition, may preferably range from 150 to 205.degree. C.
[0050] The charged amount of 4-chloro-1,8-naththalic acid anhydride
may be equivalent to the expected number of available phenolate
units in the batch. It may be more preferred to use a 5 to 50 mol %
excess of 4-chloro-1,8-naththalic acid anhydride. It may also be
advantageous to add 0 to 50 mol % (based on the amount of
4-chloro-1,8-naththalic acid anhydride) of at least one base,
whereby potassium carbonate may be preferred.
[0051] After the reaction is completed, further at least one
solvent, which preferably may be N-methyl-pyrrolidone is typically
added to cool the reaction mixture down preferably to temperatures
around 80.degree. C. At this temperature the reaction mixture,
which typically is a dispersion, is taken out of the reaction unit,
typically comprising a reaction vessel and transferred into a
separation unit. Said separation unit may preferably comprise a
filtration unit to separate the salt formed during the reaction,
e.g. potassium chloride from product. Depending on the viscosity of
the dispersion, this process may take minutes or hours such as from
30 min to 24 h. During that time the filtrate may also let to cool
down to ambient temperature (23.degree. C.). The product may then
be isolated, such as via precipitation due to addition of a
non-solvent. This can for instance be a mixture of water and at
least one polar aprotic solvent. It may be preferred to use a
mixture of water and N-methyl pyrrolidone, whereby the water is
generally used in portions greater than the N-methyl-pyrollidone.
Precipitation in a water/NMP-mixture (80/20 by weight) may be most
preferred. The obtained powder is collected, typically filtered,
and then typically washed and finally dried, whereby temperatures
from 120 to 150.degree. C. in the vacuum can be used.
[0052] Thus the general reaction scheme may preferably be
##STR00006##
wherein the variables have the meaning as defined above and n may
be from 3 to 180, preferably from 5 to 150 whereby it may be most
preferred that n is from 7 to 100.
[0053] For example, PESU containing end groups of formula I may be
obtained as depicted schematically:
##STR00007##
[0054] It may be preferred that the molding composition
comprises
(A) from 5 to 95% by weight of at least one polyarylene ether
sulfone comprising endgroups of formula I, (B) from 5 to 95% by
weight of at least one polyamide, and optionally at least one
further component, where the total of the proportions by weight of
all components is 100%, based on the molding composition.
[0055] It may be preferred that the molding composition comprises
(A) from 5 to 95% by weight of at least one PNA, whereby it may be
more preferred that it comprises (A) from 7.5 to 50% by weight,
such as from 10 to 30% by weight of at least one PNA. It may even
be more preferred that the molding composition comprises (A) from
12.5 to 25% by weight of at least one PNA. Thereby the total
proportions of all components is 100% by weight, based on the
molding composition.
[0056] The at least one polyarylether sulfone comprising end groups
of formula I used as component A in the moldings composition is
described in detail above, including possible preferences in its
structure. Thus the repeat units, the amount and the nature of end
groups is as described above and the PNA listed in Table 1 may be
particularly preferred.
[0057] As component B) the molding composition may preferably
comprise from 0 to 90% by weight at least one polyamide, whereby it
may be more preferably from 25 to 70 such as from 30 to 65% by
weight. The molding composition even more preferably comprise (B)
from 35 to 60% by weight of at least one polyamide. Thereby the
total proportions of all components is 100% by weight, based on the
molding composition.
[0058] The at least one polyamide contained in the molding
composition disclosed herein generally has a viscosity number of
from 90 to 350, which may preferably be from 110 to 240 ml/g
determined in a 0.5 wt % solution in 96 wt % sulfuric acid at
25.degree. C. in accordance with DIN EN ISO 307 (August 2013).
[0059] Preference is generally given to a at least one
semicrystalline or amorphous resin having a olecular weight (weight
average) of at least 5000, such as are described in U.S. Pat. Nos.
2,071,250, 2,071,251, 2,130,523, 2,130,948, 2,241,322, 2,312,966,
2,512,606 and 3,393,210.
[0060] Examples thereof include polyamides derived from lactams
having 7 to 13 ring members, such as polycaprolactam,
polycaprylolactam and polylaurolactam and also polyamides obtained
by reacting at least one dicarboxylic acid with at least one
diamine while others are possible.
[0061] Usable as the at least one dicarboxylic acid are
alkanedicarboxylic acids having 6 to 12 and in particular 6 to 10
carbon atoms and aromatic dicarboxylic acids. Mention will be made
here only of adipic acid, azelaic acid, sebacic acid, dodecanedioic
acid and terephthalic and/or isophthalic acid as acids.
[0062] Suitable at least one diamine include in particular alkane
diamines having 6 to 12 and in particular 6 to 8 carbon atoms and
also m-xylylenediamine (MXDA) (for example a 1:1 molar ratio of
MXDA with adipic acid), di-(4-aminophenyl)methane,
di-(4-aminocyclohexyl)methane, 2,2-di-(4-aminophenyl)propane,
2,2-di-(4-aminocyclohexyl)propane and/or
1,5-diamino-2-methylpentane.
[0063] The at least one polyamide which may be preferred is
polyhexamethylene adipamide, polyhexamethylene sebacamide or
polycaprolactam or a mixture thereof. Also preferred may be
copolyamides 6/66, especially with a proportion of caprolactam
units of from 5 to 95 wt %.
[0064] Further suitable at least one polyamide is preferably
obtainable from .omega.-aminoalkyl nitriles, for example
aminocapronitrile (PA 6) and adipodinitrile with
hexamethylenediamine (PA 66) by so-called direct polymerization in
the presence of water, as described in DE-A 10313681, EP-A 1198491
and EP 922065 for example.
[0065] Also useful at least one polyamide is typically obtainable,
for example, by condensation of 1,4-diaminobutane with adipic acid
at elevated temperature (polyamide-4,6). Production processes for
polyamides having this structure are described in EP-A 38 094. EP-A
38 582 and EP-A 39 524 for example.
[0066] Also suitable at least one polyamide may be obtainable by
copolymerization of two or more of the abovementioned monomers or
mixtures of a plurality of polyamides in any desired mixing ratio.
Particular preference is given to mixtures of polyamide 66 with
other polyamides, in particular copolyamides 6/66.
[0067] Furthermore, at least one partially aromatic copolyamide
such as PA 6/6T and PA 66/6T having a triamine content of generally
less than 0.5 and typically preferably less than 0.3 wt % have
often proven particularly advantageous (see EP-A 299 444). Further
the at least one polyamide may be at least one
high-temperature-resistant polyamide disclosed in EP-A 19 94 075
(PA 6T/6I/MXD6).
[0068] The at least one polyamide may preferably be at least one
partly aromatic copolyamide having a low triamine content which may
be produced by the processes described in EP-A 129 195 and 129
196.
[0069] The at least one polyamide which may be used as component
(B) of the molding may be chosen from the following non-exhaustive
list which contains the above cited, and also additional,
polyamides:
AB polymers: PA 4 pyrrolidone PA 6 .epsilon.-caprolactam PA 7
ethanolactam PA 8 caprylolactam PA 9 9-aminopelargonic acid PA 11
11-aminoundecanoic acid PA 12 laurolactam AA/BB polymers: PA 46
tetramethylenediamine, adipic acid PA 66 hexamethylenediamine,
adipic acid PA 69 hexamethylenediamine, azelaic acid PA 610
hexamethylenediamine, sebacic acid PA 612 hexamethylenediamine,
decanedicarboxylic acid PA 613 hexamethylenediamine,
undecanedicarboxylic acid PA 1212 1,12-dodecanediamine,
decanedicarboxylic acid PA 1313 1,13-diaminotridecane,
undecanedicarboxylic acid PA 6T hexamethylenediamine, terephthalic
acid PA 9T 1,9-nonanediamine, terephthalic acid PA MXD6
m-xylylenediamine, adipic acid PA 6I hexamethylenediamine,
isophthalic acid PA 6-3-T trimethylhexamethylenediamine,
terephthalic acid
PA 6/6T (see PA 6 and PA 6T)
PA 6/66 (see PA 6 and PA 66)
PA 6/12 (see PA 6 and PA 12)
PA 66/6/610 (see PA 66, PA6 and PA 610)
PA 6I/6T (see PA 6I and PA 6T)
[0070] PA PACM 12 diaminodicyclohexylmethane, laurolactam
PA 6I/6T/PACM as PA 6I/6T+diaminodicyclohexylmethane
[0071] PA 12/MACMI laurolactam, dimethyldiaminodicyclohexylmethane,
isophthalic acid PA 12/MACMT laurolactam,
dimethyldlaminodicyclohexylmethane, terephthalic acid PA PDA-T
phenylenediamine, terephthalic acid
[0072] The molding composition may optionally comprise component C)
from 5 to 95% by weight at least one polyarylene ether sulfone
which differs from the at least one PNA with respect to its end
groups and possibly also in its structure. For instance it may be
preferred that the molding composition comprises (C) from 9.5 to
57% by weight of said polyarylene ether sulfone, whereby it may be
more preferred that it comprises (C) from 14 to 49% by weight, such
as from 15 to 26.5% by weight of polyarylene ether sulfone. It may
even be more preferred that the molding composition comprises (C)
from 16 to 26% by weight polyarylene ether sulfone. Thereby the
proportions are based on a total of 100% by weight of components
(A) to (F).
[0073] Said difference may be in percentage of endgroups of formula
I. Thus while at least one PNA with a high percentage of endgroups
of formula I may be used as component (A) at least one PNA with a
lower or low percentage of endgroups of formula I may be used as
component (C). It may be preferred that the at least one
polyarylene ether sulfone used as component (C) does not have
endgroups of formula I. The at least one polyarylene ether sulfone
used as component (C) may--except for the amount or the nature of
the end groups--be otherwise of the same structural nature or may
have a different structure. For instance, the at least one
polyarylene ether sulfone used as component (C) may be composed of
different repeat units, may have a different repeat unit
distribution or differ in molecular weight or molecular weight
distribution. Preference may usually be given to at least one
polyarylene ether sulfone having a structure which allows it to be
miscible with the at least one PNA used as component (A).
[0074] Generally, it is preferred that the polyarylether sulfone
used as component C is composed of at least one repeat unit of
general formula II.
[0075] It may be preferred that the polyarylene ether sulfone
comprises at least one of the repeat units IIa to IIo. Other units,
in addition to the units IIa to IIo that may preferably be present,
are those in which one or more 1,4-phenylene units deriving from
hydroquinone have been replaced by 1,3-phenylene units deriving
from resorcinol, or by naphthylene units deriving from
dihydroxynaphthalene.
[0076] Units of the general formula II that may be particularly
preferred are the units IIa, IIg, and IIk. It may also be
particularly preferable that the polyarylene ether sulfone is in
essence composed of one type of unit of the general formula II,
whereby one type may in particular be selected from IIa, IIg, and
IIk.
[0077] The polyarylene ether sulfone may particularly preferably be
composed of repeat units where Ar is 1,4-phenylene, t is 1, q is 0,
T is a chemical bond, and Y is SO2. If this polyarylene ether
sulfone does not have any endgroups of formula I is also termed
polyphenylene sulfone (PPSU) (formula IIg).
[0078] The polyarylene ether sulfone may particularly preferably be
composed of repeat units where Ar is 1,4-phenylene, t is 1, q is 0,
T is C(CH3)2, and Y is SO2. If this polyarylene ether sulfone does
not have any end groups of formula I is also termed polysulfone
(PSU) (formula IIa).
[0079] The polyarylene ether sulfone may particularly preferably be
composed of repeat units where Ar is 1,4-phenylene, t is 1, q is 0,
T and Y are SO2. If this polyarylene ether sulfone does not have
any end groups of formula I it is also termed polyether sulfone
(PESU) (formula IIk).
[0080] The molding composition may optionally comprise component
(D) from 0 to 70% by weight at least one fibrous or particulate
filler. If present it may be preferable that the composition
comprises (D) from 10 to 70% by weight. It may be more preferred
that it comprises (D) from 10 to 62.5% by weight, such as from 10
to 50% by weight. It may be even more preferred that the molding
composition comprises (D) from 12.5 to 40% by weight, Thereby the
proportions are based on a total of 100% by weight of components
(A) to (F).
[0081] The molding composition can in particular comprise at least
one particulate or fibrous filler, particular preference may be
given to fibrous fillers.
[0082] Typically preferred at least one fibrous filler is carbon
fiber, potassium titanate whisker, aramid fiber, and generally
particularly preferably glass fiber. If at least one glass fiber is
used, it can have been equipped with a size, preferably with a
polyurethane size, and with a coupling agent, to improve
compatibility with the matrix material. The diameter of the at
least one carbon fiber and/or glass fiber used is generally in the
range from 6 to 20 .mu.m. Component (D) is therefore generally
particularly preferably composed of at least one glass fiber.
[0083] The form in which the at least one glass fiber is
incorporated can either be that of short glass fibers or else that
of continuous-filament fibers (rovings). The average length of the
at least one glass fiber in the finished injection molding is
preferably in the range from 0.08 to 2 mm.
[0084] The at least one carbon fiber and/or glass fiber can also be
used in the form of textiles, mats, or glass-silk rovings.
[0085] Suitable at least one particulate filler may be amorphous
silica, carbonate, such as magnesium carbonate and chalk, powdered
quartz, mica, various silicates, such as clays, muscovite, biotite,
suzoite, tin maletite, talc, chlorite, phlogopite, feldspar,
calcium silicates, such as wollastonite, or aluminum silicates,
such as kaolin, particularly calcined kaolin.
[0086] Generally preferred at least one particulate filler may be
those in which at least 95% by weight, preferably at least 98% by
weight, of the particles have a diameter (greatest diameter through
the geometric center), determined on the finished product, of less
than 45 .mu.m, preferably less than 40 .mu.m, where the value known
as the aspect ratio of the particles is in the range from 1 to 25,
preferably in the range from 2 to 20, determined on the finished
product. The aspect ratio is the ratio of particle diameter to
thickness (greatest dimension to smallest dimension, in each case
through the geometric center).
[0087] The particle diameters can by way of example be determined
here by recording electron micrographs of thin layers of the
polymer mixture and evaluating at least 25 filler particles,
preferably at least 50. The particle diameters can also be
determined by way of sedimentation analysis, as in Transactions of
ASAE, page 491 (1983). Sieve analysis can also be used to measure
the proportion by weight of the fillers with diameter less than 40
.mu.m.
[0088] The at least one particulate filler may particularly
preferably comprise talc, kaolin, such as calcined kaolin, or
wollastonite, or a mixture of two or all of said fillers. Among
these, particular preference is typically given to talc having a
proportion of at least 95% by weight of particles with diameter
smaller than 40 .mu.m and with aspect ratio of from 1.5 to 25, in
each case determined on the finished product. Kaolin preferably can
have a proportion of at least 95% by weight of particles with
diameter smaller than 20 .mu.m and preferably can have an aspect
ratio of from 1.2 to 20, which in each case is determined on the
finished product.
[0089] The molding compositions may, if desired, comprise as
component (E) at least one impact-modifying rubber. The proportion
thereof may be from 0 to 30% by weight. If present it may be in
particular from 0 to 25% by weight, whereby it may be more
preferably that the molding composition comprises (D) from 0 to 20%
by weight, such as from 5 to 15% by weight. It may even be more
preferred that the molding composition comprises (D) from 6 to 14
by weight of at least one impact modifying rubber. Thereby the
total proportions are based on a total of 100% by weight of
components (A) to (F).
[0090] Preferred at least one rubber which increases the toughness
of molding compositions usually has two significant features: it
comprises an elastomeric fraction which has a glass transition
temperature below -10.degree. C., preferably below -30.degree. C.,
and it contains at least one functional group which can interact
with the polyamide or the PNA or both. In case it interacts with
the PNA it usually also interacts with the polyether sulfone
component C. Examples of suitable functional groups are carboxylic
acid, carboxylic anhydride, carboxylic ester, carboxamide,
carboximide, amino, hydroxyl, epoxy, urethane and oxazoline
groups.
[0091] Generally preferred at least one functionalized rubber D
include functionalized polyolefin rubbers built up from the
following components: [0092] d1) from 40 to 99% by weight of at
least one alpha-olefin having from 2 to 8 carbon atoms; [0093] d2)
from 0 to 50% by weight of a diene; [0094] d3) from 0 to 45% by
weight of at least one C1-C12-alkyl ester of acrylic or methacrylic
acid, or mixtures of esters of this type; [0095] d4) from 0 to 40%
by weight of at least one ethylenically unsaturated C2-C20 mono- or
dicarboxylic acid or of a functional derivative of an acid of this
type; [0096] d5) from 1 to 40% by weight of at least one monomer
containing epoxy groups; and [0097] d6) at least one monomer
capable of free-radical polymerization.
[0098] Examples of suitable at least one alpha-olefin (d1) are
ethylene, propylene, 1-butylene, 1-pentylene, 1-hexylene,
1-heptylene, 1-octylene, 2-methylpropylene, 3-methyl-1-butylene and
3-ethyl-1-butylene. Ethylene and propylene may be preferred.
[0099] Examples of suitable at least one diene monomer (d2) are
conjugated dienes having from 4 to 8 carbon atoms, such as isoprene
and butadiene, non-conjugated dienes having from 5 to 25 carbon
atoms, such as 1,4-pentadiene, 1,4-hexadiene, 1,5-hexadiene,
2,5-dimethyl-1,5-hexadiene and 1,4-octadiene, cyclic dienes, such
as cyclopentadiene, cyclohexadienes, cyclooctadienes and
dicyclopentadiene, and also alkenylnorbornenes, such as
5-ethylidene-2-norbornene, 5-butylidene-2-norbornene,
2-methallyl-5-norbornene and 2-isopropenyl-5-norbornene, and
tricyclodienes, such as 3-methyltricyclo
[5.2.I.02.6]-3,8-decadiene, or mixtures of these. Preference is
given to 1,5-hexadiene, 5-ethylidenenorbornene and
dicyclopentadiene. The diene content can generally be from 0 to 50%
by weight, whereby it may be preferred that it is from 0.5 to 50%
by weight, whereby it may be particularly preferably from 2 to 20%
by weight and more particularly preferably from 3 to 15% by weight,
based on the total weight of the olefin polymer.
[0100] Examples of suitable at least one ester (d3) are methyl,
ethyl, propyl, n-butyl, isobutyl, 2-ethylhexyl, octyl and decyl
acrylates and the corresponding methacrylates. Among these
particular preference may be given to methyl, ethyl, propyl,
n-butyl and 2-ethylhexyl acrylate and methacrylate.
[0101] Instead of the at least one ester (d3), or in addition to
these, the olefin polymers may also comprise acid-functional and/or
latently acid-functional monomers in the form of at least one
ethylenically unsaturated mono- or dicarboxylic acid (d4).
[0102] Examples of at least one monomer (d4) are acrylic acid,
methacrylic acid, tertiary alkyl esters of these acids, in
particular tert-butyl acrylate, and dicarboxylic acids, such as
maleic acid and fumaric acid, and derivatives of these acids, and
also their half-esters.
[0103] For the purposes of the invention, latently acid-functional
monomers are those compounds which under the conditions of the
polymerization or during incorporation of the olefin polymers into
the molding compositions form free acid groups. Examples of these
are anhydrides of dicarboxylic acids having from 2 to 20 carbon
atoms, in particular maleic anhydride, and tertiary C1-C12-alkyl
esters of the abovementioned acids, in particular tert-butyl
acrylate and tert-butyl methacrylate. Ethylenically unsaturated
dicarboxylic acids and anhydrides (d4) have the following formulae
III and IV:
##STR00008##
where R5, R6, R7 and R8, independently of one another, are H or C1
to C6-alkyl. Monomers d5 containing epoxy groups have the following
formulae V and VI
##STR00009##
where R9, R10, R11 and R12, independently of one another, are H or
C1 to C6-alkyl, m is an integer from 0 to 20, and p is an integer
from 0 to 10, R5 to R12 may preferably be hydrogen, m may
preferably be 0 or 1 and p may preferably be 1.
[0104] Typically preferred at least one compound (d4) and,
respectively, (d5) may be maleic acid, fumaric acid and maleic
anhydride and, respectively, alkenyl glycidyl ethers and vinyl
glycidyl ether.
[0105] Generally particularly preferred compounds of the formulae
III and IV and, respectively, V and VI can be maleic acid and
maleic anhydride and, respectively, acrylates and/or meth-acrylates
both of which contain epoxy groups, in particular glycidyl acrylate
and glycidyl methacrylate.
[0106] It may be particularly preferred that the at least one
olefin polymer are those made from 49.9 to 98.9% by weight, whereby
it may in particular be from 59.85 to 94.85% by weight, of
ethylene, and from 1 to 50% by weight, in particular from 5 to 40%
by weight, of an ester of acrylic or methacrylic acid, and from 0.1
to 20.0% by weight, in particular from 0.15 to 15% by weight, of
glycidyl acrylate and/or glycidyl methacrylate, acrylic acid and/or
maleic anhydride.
[0107] Particularly suitable at least one functionalized rubber (D)
may for instance be an ethylene-methyl methacrylate-glycidyl
methacrylate polymer, ethylene-methyl acrylateglycidyl methacrylate
polymer, ethylene-methyl acrylate-glycidyl acrylate polymer or an
ethylene-methyl methacrylate-glycidyl acrylate polymer or a mixture
of these.
[0108] Examples of the other at least one monomer (d6) are for
instance vinyl esters and vinyl ethers and mixtures of these.
[0109] The polymers described above may be prepared by processes
known per se or accessible to the person skilled in the art by
applying the general knowledge, for instance preferably by random
copolymerization at high pressure and elevated temperature.
[0110] The melt index of the copolymers may generally be from 1 to
80 g/min 10 min (measured at 190.degree. C. and 2.16 kg load).
[0111] Furthermore, functionalized
ethylene-.alpha.-olefin-copolymers like
ethylene-propylene-grafted-maleic anhydride or
ethylene-1-butene-grafted maleic anhydride can also be used as
impact modifiers.
[0112] Core-shell graft rubbers generally are another group of
suitable at least one rubber (D). These are graft rubbers which
typically can be prepared in emulsion and composed of at least one
hard and one soft constituent. Usually, a hard constituent is at
least one polymer with a glass transition temperature of at least
25.degree. C., and usually a soft constituent is at least one
polymer with a glass transition temperature of not more than
0.degree. C. These products generally have a structure made from a
core (graft base) and from at least one shell (graft), and the
structure is typically a result of the sequence of addition of the
monomers. The soft constituent generally derives from butadiene,
isoprene, at least one alkyl acrylate, at least one alkyl
methacrylate or at least one siloxane and, if desired, at least one
other comonomer. Suitable siloxane cores may be prepared, for
example, starting from cyclic oligomeric octamethyltetrasiloxane or
from tetravinyltet-ramethyltetrasiloxane. These may, for example,
be reacted with y-mercaptopropylmethyldimethoxysilane in a
ring-opening cationic polymerization, preferably in the presence of
sulfonic acids, to give the soft siloxane core. The at least one
siloxane may also be crosslinked by, for example, carrying out the
polymerization in the presence of at least one silane having at
least one hydrolyzable group, such as halo or alkoxy, for example
tetraethoxysilane, methyltrimethoxysilane or
phenyltrimethoxysilane. Examples of suitable at least one comonomer
for this are styrene, acrylonitrile and crosslinking or grafting
monomers having more than one polymerizable double bond, for
example diallyl phthalate, divinylbenzene, butanediol dia-crylate
or triallyl (iso) cyanurate. The hard constituent generally derives
from styrene, alpha-methylstyrene or from copolymers of these, and
it may be preferred that the at least one comonomer here is
acrylonitrile, methacrylonitrile or methyl methacrylate.
[0113] It may be preferred that the at least one core-shell graft
rubber comprises a soft core and a hard shell or a hard core, a
first soft shell and at least one further hard shell. The
incorporation of at least one functional group here, such as
carbonyl, carboxylic acid, anhydride, amide, imide, carboxylic
ester, amino, hydroxyl, epoxy, oxazoline, urethane, urea, lactam or
halobenzyl, may preferably take place by adding at least one
suitably functionalized monomer during the polymerization of the
final shell.
[0114] Examples of at least one suitable functionalized monomer are
maleic acid, maleic anhydride, half-esters or diesters, or maleic
acid, tert-butyl (meth)acrylate, acrylic acid, glycidyl
(meth-)acrylate and vinyloxazoline. The proportion of the at least
one monomer with functional groups is generally from 0.1 to 25% by
weight, whereby it may be preferably from 0.25 to 15% by weight,
based on the total weight of the core-shell graft rubber. The
weight ratio of soft to hard constituents is generally from 1:9 to
9:1, whereby it may be preferably from 3:7 to 8:2.
[0115] Rubbers of this type are known per se or accessible to the
person skilled in the art by making use of the general knowledge
and are described, for example, in EP-A 208 187.
[0116] Thermoplastic polyester elastomers are another group of
suitable at least one impact modifier. For the purposes of the
invention, polyester elastomers are segmented copolyether-esters
which typically may comprise long-chain segments generally deriving
from poly(alkylene) ether glycols and short-chain segments which
typically may derive from low-molecular weight diols and
dicarboxylic acids. Products of this type are known per se or
accessible to the person skilled of the by application of the
general knowledge and are described for example in U.S. Pat. No.
3,651,014. Corresponding products are also available commercially
as Hytrel.RTM. (Du Pont), Amitel.RTM. (Akzo) and Pelprene.RTM.
(Toyobo Co. Ltd.).
[0117] The molding composition may optionally comprise component
(F) from 0 to 40% by weight at least one auxiliary. If present it
may be preferable that the composition comprises (F) from 0.5 to
40% by weight. It may be more preferred that it comprises (F) from
10 to 40% by weight, such as from 1 to 20% by weight. It may be
even more preferred that the molding composition comprises (F) from
1 to 15% by weight, Thereby the proportions are based on a total of
100% by weight of components (A) to (F).
[0118] The at least one auxiliary may in particular be at least one
processing aid, pigment, stabilizer, flame retardant, or a mixture
of various additives. Other examples of conventional additives are
at least one oxidation retarder, agent to counter decomposition by
heat and decomposition by ultraviolet light, lubricant and
mold-release agent, dye, and plasticizer which may be use alone or
in any combination with any other auxiliary.
[0119] The amount comprised of at least one pigments and/or at
least one dye is generally from 0 to 6% by weight, preferably it
may be from 0.05 to 5% by weight, and in particular it may be from
0.1 to 3% by weight, based on the total of the % by weight values
for components (A) to (F).
[0120] Pigments for the coloring of thermoplastics are well known,
see for example R. Gachter and H. Muller, Taschenbuch der
Kunststoff additive [Plastics additives handbook], Carl Hanser
Verlag, 1983, pages 494 to 510. A first preferred group of pigments
that may be mentioned are white pigments, such as zinc oxide, zinc
sulfide, white lead [2PbCO.sub.3.Pb(OH).sub.2], lithopones,
antimony white, and titanium dioxide. Of the two most familiar
crystalline forms of titanium dioxide (rutile and anatase), it is
typically in particular the rutile form which is used for white
coloring of the molding compositions disclosed. Black color
pigments which can be used according to the invention are iron
oxide black (Fe.sub.3O.sub.4), spinel black [Cu(Cr,
Fe).sub.2O.sub.4], manganese black (a mixture composed of manganese
dioxide, silicon dioxide, and iron oxide), cobalt black, and
antimony black, and also it may be particularly preferably carbon
black, which is mostly used in the form of furnace black or gas
black. In this connection see G. Benzing, Pigmente fur
Anstrichmittel [Pigments for paints], Expert-Verlag (1988), pages
78ff.
[0121] Particular color shades can for instance be achieved by
using inorganic chromatic pigments, such as chromium oxide green,
or organic chromatic pigments, such as azo pigments or
phthalocyanines. Pigments of this type are known to the person
skilled in the art.
[0122] Examples of the at least one oxidation retarder and/or the
at least one heat stabilizers which can be added to the molding
composition are halides of metals of group I of the Periodic Table
of the Elements, e.g. sodium halides, potassium halides, or lithium
halides, examples being chlorides, bromides, or iodides. Zinc
fluoride and zinc chloride can moreover be used. It is also
possible to use sterically hindered phenols, hydroquinones,
substituted representatives of said group, secondary aromatic
amines, if appropriate in combination with phosphorus-containing
acids, or to use their salts, or a mixture of said compounds,
preferably in concentrations up to 1% by weight, based on the total
of the % by weight values for components (A) to (F).
[0123] Examples of the at least one UV stabilizer are various
substituted resorcinols, salicylates, benzotriazoles, and
benzophenones, the amounts generally used of these being up to 2%
by weight, based on the total of the % by weight values for
components (A) to (F).
[0124] At least one lubricant and/or at least one mold-release
agent, the amounts of which added may generally be up to 1% by
weight, based on the total of the % by weight values for components
(A) to (F), are for example stearyl alcohol, alkyl stearates, and
stearamides, and also esters of pentaerythritol with long-chain
fatty acids. It is also possible to use dialkyl ketones, such as
distearyl ketone.
[0125] It can be preferable that the molding composition comprises
from 0.1 to 2% by weight, whereby it may be more preferably from
0.1 to 1.75% by weight, particularly preferably it may be from 0.1
to 1.5% by weight and in particular it may be from 0.1 to 0.9% by
weight (based on the sum of the % by weight values of components
(A) to (F)) of stearic acid and/or of stearates. In principle it is
also possible to use other stearic acid derivatives, for example
esters of stearic acid.
[0126] Stearic acid is preferably produced via hydrolysis of fats.
The products thus obtained are usually mixtures composed of stearic
acid and palmitic acid. These products therefore have a wide
softening range, for example from 50 to 70.degree. C., as a
function of the constitution of the product. Preference may be
given to using products with more than 20% by weight content of
stearic acid, particularly preferably more than 25% by weight. It
is also possible to use pure stearic acid (more than 98% by
weight).
[0127] Component (F) can moreover also include stearates. Stearates
can be produced either via reaction of corresponding sodium salts
with metal salt solutions (e.g. CaCl.sub.2, MgCl.sub.2, aluminum
salts) or via direct reaction of the fatty acid with metal
hydroxide (see for example Baerlocher Additives, 2005). It is
typically preferable to use aluminum tristearate.
[0128] Further at least one additive that can be used are also
those known as nucleating agents, an example being talc powder.
TABLE-US-00002 Component Component Component A* Component B
Component C D** E*** Component F Composition Amount Amount Amount
Amount Amount Amount Number [% by wt] Type [% by wt] Type [% by wt]
[% by wt] [% by wt] Type [% by wt] 1 5 to 95 0 PESU 5 to 95 0 0 0 2
5 to 50 PA 9T 25 to 50 PESU 5 to 70 3 5 to 50 PA 6T66 25 to 50 PESU
5 to 70 4 5 to 50 PA 6T6I 25 to 50 PESU 5 to 70 5 5 to 50 PESU 35
to 85 10 to 60 6 5 to 50 PA 9T 5 to 70 PESU 15 to 80 10 to 62.5 7 5
to 50 PA 9T 5 to 60 PESU 30 to 85 5 to 25 8 5 to 50 PA 9T 5 to 60
PESU 10 to 69.9 20 to 60 Pigment 0.1 to 3 9 5 to 50 PA 9T 5 to 60
PPSU 10 to 69.9 20 to 60 Pigment 0.1 to 3 10 5 to 50 PA 9T 5 to 60
PESU 30 to 84.9 5 to 25 Pigment 0.1 to 3 11 5 to 50 PA 9T 5 to 60
PESU 10 to 69.8 20 to 60 Pigment 0.1 to 3 Heat- 0.1 to 2 Stabilizer
*PESU-NA comprising 30 to 40% NA endgroups **E-Glass fiber
***EB-g-MAH
[0129] Components (A) to (F) can be mixed in any desired
sequence.
[0130] The molding composition can be produced by processes known
to the person skilled in the art or accessible to him by general
knowledge, for example extrusion. The molding composition can by
way of example be produced by mixing the starting components in at
least one conventional mixing apparatus, such as screw-based
extruder, preferably twin-screw extruder, Brabender mixer, or
Banbury mixer, or else kneader, and then extruding it. The
extrudate is typically cooled and comminuted. The sequence of the
mixing of the components can be varied, and it is therefore
possible to mix two or more than two components in advance, but it
is also possible to mix all of the components together.
[0131] In order to obtain a mixture with maximum homogeneity,
intensive and thorough mixing is generally advantageous. Average
mixing times needed for this are generally from 0.2 to 30 minutes
at temperatures of from 290 to 380.degree. C., preferably it may be
from 300 to 370.degree. C. The extrudate is generally cooled and
granulated.
[0132] The thermoplastic molding composition can advantageously be
used for the manufacture of a fiber, film, foam or shaped article.
Due to the good current tracking index the molding composition is
generally particularly suitable for producing electric or
electronic components. As the molding composition has a high
temperature resistance and good chemical resistance they may in
particular lend itself for the production of electric or electronic
components, which are exposed to elevated temperatures and/or
chemicals. Generally, the products which may be obtained from the
molding composition can be industry items such as in the vehicle
sector e.g. in automobiles or planes. Likewise, they may be
household items such as appliances or items with food contact.
Furthermore, battery housings, parts for plumbing, energy absorbing
foams can also be produced with the molding composition.
EXAMPLES
[0133] The examples below provide further explanation of the
invention, but do not restrict the same.
Components of the Molding Compositions
Component A1
[0134] The preparation of the polyether sulfone comprising end
groups of formula I (PESU-NA) was carried out according to the
following procedure:
[0135] In a vessel equipped with a stirrer, Dean-Stark-trap,
nitrogen-inlet and temperature control, 278.27 g (0.969 mol)
4,4'-dichlorodiphenylsulfone (DCDPS), 250.17 g (1.00 mol)
4,4'-dihydroxydiphenylsulfone (DHDPS), and 152.03 g (1.10 mol)
potassium carbonate (particle size 39.3 .mu.m) was suspended under
nitrogen atmosphere in 1000 ml NMP. Under stirring the mixture was
heated up to 190.degree. C. 30 l/h Nitrogen is purged through the
mixture and the mixture is kept at 190.degree. C. for 6 h. After
that time 15.34 g (0.066 mol) 4-Chloro-1,8-naphthalic anhydride
dissolved in NMP (10%) are added at 190.degree. C. and the reaction
continues for another 2 h. After this time 500 ml NMP are added to
cool down the mixture. Under nitrogen the mixture is allowed to
cool down below 60.degree. C. After filtration the polymer solution
is precipitated in water. The precipitated product is extracted
with hot water (20 h at 85.degree. C.) and dried at 120.degree. C.
for 24 h under reduced pressure.
[0136] The V.N. of the product was 54.7 ml/g, the amount of
NA-endgroups 35% (determined by 1H-NMR).
Component AV
[0137] Polyethersulfone prepared according to the process given in
example 1 of WO97/04018, having a V.N of 50.2 ml/g and 0.65 wt.-%
phtahlic anhydride-endgroups, which corresponds to 37%
PhA-endgroups.
Component B
[0138] As component B a Polyamide 9T with a viscosity number of 120
ml/g (measured at 25.degree. C. in conc. H.sub.2SO.sub.4) was
used.
Component C
[0139] As component C a polyether sulfone (PESU) having a viscosity
number of 49.0 ml/g was used. The used product had 0.19 wt.-%
Cl-endgroups and 0.23 wt.-% OCH.sub.3-Endgroups (1H-NMR).
Component D
[0140] Glass fibres, chopped strands (length 4.5 mm) with a
diameter of 10 .mu.m and a PU-based sizing.
Component E
[0141] Impact modifier based on polyethylene-co-1-butene, grafted
with maleic acid/maleic anhydride, having a MVR-value (190.degree.
C./2.16 kg) of 0.97 ml/10'.
Component F1
[0142] 4,4'-Bis(.alpha.,.alpha.-dimethylbenzyl)diphenyl-amine,
melting point 98-100.degree. C.
Component F2
Sodiumhypophosphite
Production and Testing of the Molding Compositions
[0143] Compounding was done using a twin screw extruder (ZSK 30),
the barrel temperatures were set to keep the melt temperature below
350.degree. C. Molding of the test samples was done at a melt
temperature of 340.degree. C. and a mold temperature of 120.degree.
C. Tensile testing was done according to DIN EN ISO 527-1 (Juni
2012) (E-Modulus, strength, tensile elongation).
[0144] Impact strength was tested according to DIN EN ISO 179 1eU
(June 2012), while notched impact was tested according to DIN EN
ISO 179 1eA (June 2012). The viscosity of the melt was tested
according by MVR-measurements (DIN EN ISO 1133-1 (March 2012),
360.degree. C./5 kg).
[0145] The CTI was measured according to IEC 60112 (January 2003)
on samples having a thickness of 4 mm.
[0146] To assess the chemical resistance of the compounds, pieces
of a molded sample (2 g) were placed in 100 ml N-methyl-pyrrolidone
(NMP) at 23.degree. C. for 48 h. After that time the non-soluble
material was filtered of, washed carefully with another 250 ml NMP,
then dried for 24 h in the vacuum to determine the part of
non-soluble material.
[0147] The solution viscosity (V.N.) of the PNA was determined
using a solution of 0.01 g/ml in N-Methylpyrrolidon at 25.degree.
C. (DIN EN ISO 1628-1 (October 2012)).
[0148] The results of the experiments are shown in Table 1.
TABLE-US-00003 TABLE 1 Example C1* 2** C3 4 5 C6 7 C8 9 C10 A1 --
25 -- 35 17.5 -- 25 -- 16.25 -- AV -- -- -- -- -- -- -- -- 16.25 B
50 25 70 35 52.5 50 25 32.5 16.25 16.25 C 49.33 49.33 29.58 29.58
29.58 44.58 44.58 32.08 32.08 32.08 D -- -- -- -- -- -- -- 45 45 45
E -- -- -- -- 5 5 -- -- -- F1 0.65 0.65 0.4 0.4 0.4 0.4 0.4 0.4 0.4
0.4 F2 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 ISO 179
102 370 150 >400 >400 167 >400 37 63 54 1eU [kJ/m.sup.2]
ISO 179 3.4 6.8 4.6 7.5 7.1 4.2 8.9 7.4 9.5 9.1 1eA [kJ/m.sup.2]
CTI 175 250 150 225 225 175 250 250 275 225 Non-sol. 49.7 63.7 29.8
35.1 33.1 49.2 61.8 77.2 81.2 80.1 part [wt. %] *Comparative
examples **Examples according to the invention
[0149] The compositions according to the invention show an improved
mechanical performance and surprisingly superior CTI-values.
* * * * *