Stock material or miscellaneous articles – Composite – Of polyamidoester
Reexamination Certificate
2000-01-21
2001-08-14
Copenheavef, Blaine (Department: 1773)
Stock material or miscellaneous articles
Composite
Of polyamidoester
C428S474400, C428S500000, C428S502000
Reexamination Certificate
active
06274243
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to automobile exterior components. In more detail, it relates to automobile exterior components prepared from a thermoplastic resin composition, having good balance between impact resistance and fluidity and being excellent in coating heat resistance and rigidity.
In recent years, a variety of plastic materials have been used for automobile exterior components such as outside sheathing panels, hub caps, spoilers and bumpers, and requirements for such plastic materials have been rising. For example, high-level impact resistance, fluidity and rigidity are required for plastic materials used for outside sheathing panels. These exterior components are, in many cases, subjected to urethane coating or melamine coating for improving their exterior appearance. Especially, in recent years, a melamine coating, which has been used for coating steel plates for automobile bodies, is also applied for coating outside sheathing resin plates and number of such cases is increasing. Since the baking temperatures in such melamine coating is relatively high, materials to be coated are required to have high heat resistance (coating heat resistance).
Blends composed of a polyamide resin which is excellent in chemical resistance, heat resistance, abrasion resistance and the like and an ABS resin which is excellent in impact resistance, moldability and the like, namely, polyamide/ABS alloys, is proposed (Japanese Patent Publication No. 38-23476. Hereinafter, “Japanese Patent Publication No.” is abbreviated to “JP-B-”.). Since the polyamide resin and the ABS resin, however, have poor compatibility, a method in which a modified copolymer prepared by copolymerizing an unsaturated carboxylic acid with styrene and acrylonitrile is compounded to these resins has been proposed (Japanese Patent Laid-Open Publication Nos. 63-179957 and 64-158). Hereinafter, “Japanese Patent Laid-Open Publication No.” is abbreviated to “JP-A-”.). However, these materials do not sufficiently attain the object of the present invention, namely good balance between impact resistance and fluidity and excellent coating heat resistance and rigidity.
SUMMARY OF THE INVENTION
The object of the present invention is to provide automobile exterior components having good balance between impact resistance and fluidity and being excellent in rigidity and coating heat resistance in urethane coating and melamine coating.
EMBODIMENT OF THE INVENTION
The object of the present invention can be attained by an automobile exterior component prepared by performing urethane coating or melamine coating on a molded article obtained by molding a resin composition prepared by compounding an unsaturated carboxylic acid-modified copolymer having a specific reduced viscosity and a specific amount of talc with a polyamide resin and an ABS resin.
That is, the present invention provides an automobile exterior component prepared by performing urethane coating or melamine coating on a molded article obtained by molding a resin composition which comprises 10 to 80 parts by weight of a polyamide resin (A);
10 to 80 parts by weight of a grafted polymer (B) prepared by graft polymerizing a monomer mixture consisting of 50 to 90% by weight of an aromatic vinyl monomer and 10 to 50% by weight of a vinyl cyanide monomer in the presence of a diene rubber, wherein the amounts of the monomer mixture and the diene rubber are 90-20% by weight and 10-80% by weight, respectively, based on the total amount of the monomer mixture and the diene rubber;
1 to 40 parts by weight of an unsaturated carboxylic acid-modified copolymer (C) which has a reduced viscosity of 0.2 to 0.5 dl/g and is prepared by polymerizing an unsaturated carboxylic acid monomer, an aromatic vinyl monomer and a vinyl cyanide monomer, wherein the amounts of the unsaturated carboxylic acid monomer, the aromatic vinyl monomer and the vinyl cyanide monomer are 0.5-20% by weight, 50-89.5% by weight and 10-49.5% by weight, respectively, based on the total amount of the unsaturated carboxylic acid monomer, the aromatic vinyl monomer and the vinyl cyanide monomer;
0 to 50 parts by weight of a copolymer (D) prepared by polymerizing an aromatic vinyl monomer and a vinyl cyanide monomer wherein the amounts of the aromatic vinyl monomer and the vinyl cyanide monomer are 50-90% by weight and 10-50% by weight, respectively, based on the total amount of the aromatic vinyl monomer and the vinyl cyanide monomer; and
0.1 to 10% by weight, based on the total weight of (A), (B), (C) and (D), of talc.
Examples of the polyamide resin (A) used in the present invention include nylon 6, nylon 46, nylon 66, nylon 610, nylon 612, nylon 116, nylon 11, nylon 12, nylon 6I, nylon 6/66, nylon 6T/6I, nylon 6/6T, nylon 66/6T, polytrimethylhexamethyleneterephthalamide, polybis(4-aminocyclohexyl)methane dodecamide, polybis(3-methyl-4-aminocyclohexyl)methane dodecamide, polymetaxylylene adipamide, nylon 11T and polyundecamethylenehexahydroterephthalamide. The foregoing “I” and “T” in the name of the polyamide resin (A) indicate that the resin contains an isophthalic acid component and a terephthalic acid component, respectively. Among those polyamide resins, nylon 6, nylon 46, nylon 66, nylon 6T/6I, nylon 6/6T and nylon 66/6T are preferred.
In the present invention, laminar silicate-containing polyamide resins in which laminar silicates are dispersed uniformly in fine conditions can also be used as above polyamide resin (A). The term “fine conditions” used herein means the order of nano meter. The size of laminar silicates dispersed in a polyamide resin is generally in the range of from 1 to 1000 nm, preferably in the range of from 1 to 100 nm. Such a laminar silicate-containing polyamide resin can, for example, be produced by a method in which monomer used for forming polyamide are polymerized in the presence of the laminar silicate or a method in which a laminar silicate and a polyamide resin are melt kneaded. Use of a pre-treated or synthesized laminar silicate permits uniform dispersion of the laminar silicate in fine conditions. Content of the laminar silicate is not limited, although it is preferably in the range of from 0.1 to 30% by weight in the polyamide resin. Examples of such a laminar silicate include natural materials such as montmorillonite, saponite, beidellite, hectorite, nontronite, kaolinite, halloysite, talc and mica, and synthesized materials such as swellable fluorine mica described in JP-A-6-248176. Laminar silicate-containing polyamide resins usable in the present invention are described in JP-A-62-74957 and JP-A-6-248176, for example.
From the viewpoint of heat resistance and rigidity, the laminar silicate-containing polyamide resin as mentioned above and a mixtures of the laminar silicate-containing polyamide resin and other polyamide resins are especially preferred as the polyamide resin (A).
The grafted polymer (B) used in the present invention is a graft polymer prepared by a graft polymerization of a monomer mixture consisting of 50 to 90% by weight of an aromatic vinyl monomer and 10 to 50% by weight of a vinyl cyanide monomer in the presence of a diene rubber. The amounts of the monomer mixture and the diene rubber, used for the graft polymerization, are 90-20% by weight and 10-80% by weight, respectively, based on the total amount of the monomer mixture and the diene rubber.
The diene rubber which constitutes the grafted polymer (B) is a polymer prepared by polymerizing a monomer containing at least 50% by weight of a diene monomer, such as 1,3-butadiene. Preferred monomers which are copolymerizable with the diene monomer include aromatic vinyl monomers such as styrene and &agr;-methylstyrene, vinyl cyanide monomers such as acrylonitrile and methacrylonitrile and alkyl unsaturated carboxylate monomers such as methyl acrylate, ethyl acrylate and methyl methacrylate. Examples of the diene rubber include polybutadiene, butadiene-styrene copolymers, butadiene-acrylonitrile copolymers and butadiene-methyl methacrylate copolymers. Although there is no particular
Akiyama Tomoyoshi
Aoki Hiromichi
Nakajima Osamu
Takeuchi Atsushi
Copenheavef Blaine
Davis Stevens
Miller & Mosher, L.L.P.
Nippon A & L Incorporated
Paulraj Christopher
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