Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2001-02-02
2004-03-23
Yoon, Tae H. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C523S500000, C525S430000, C525S449000
Reexamination Certificate
active
06710106
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a molding composition suitable for production of cores of automobile interior materials, sound absorbers of air conditioners, glass mat, constructional sound insulators, and the like.
BACKGROUND OF THE INVENTION
Cores of automobile interior materials, sound absorbers of air conditioners, glass mat, constructional sound insulators, and the like are produced from molding compounds mainly comprising fiber, a phenolic resin, and an amine-based curing agent to secure sufficient strength (see, for example, JP-A-57-55962 (The term “JP-A” as used herein means an “unexamined published Japanese patent application”) and JP-A-7-1666). However, phenolic resins react or decompose to produce formaldehyde, and amine-based curing agents have the problem of smell.
Powdered molding compositions comprising a diallyl phthalate prepolymer and/or a crystalline unsaturated polyester resin, fiber, and a curing agent are known (see JP-A-5-169475). However, the diallyl phthalate prepolymer has a low iodine value and fails to achieve a high crosslinking density, resulting in the production of a molded article having insufficient strength.
A molding composition comprising a non-crystalline unsaturated polyester and an ethylenically unsaturated group-containing monomer having compatibility with the unsaturated polyester and a molding composition further comprising a polymerization initiator are also known (see JP-B-2-31090 (The term “JP-B” as used herein means an “examined Japanese patent application”)). Although any ethylenically unsaturated group-containing monomer such as styrene compatible with an unsaturated polyester acts as a crosslinking agent to provide a molded article with improved strength, it has the problems of smell and safety.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a molding composition suitable for production of a molded article having practically sufficient strength and heat resistance and improved safety and smell and such a molded article.
The present invention relates
(1) a molding composition comprising an aggregate [Component (A)], a linear unsaturated polyester [Component (B)] and/or a linear unsaturated polyester polyamide [Component (C)], and a radical generator [Component (D)], wherein Components (B) and (C) comprise an alkylene (having from 2 to 4 carbon atoms) oxide adduct of bisphenol A (average added number of mols: 1 to 10) in an amount of from 3 to 50 mol % based on the total amount of constituent monomers and
(2) a molded article obtained by molding the molding composition defined in item (1) above.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, the use of a linear unsaturated polyester [Component (B)] and/or linear unsaturated polyester polyamide [Component (C)] comprising an alkylene (having from 2 to 4 carbon atoms) oxide adduct of bisphenol A (average added number of mols: 1 to 10) in an amount of from 3 to 50 mol % based on the total amount of constituent monomers and preferably having an iodine value of from 70 to 150 makes it possible to obtain a molded article having practically sufficient strength and heat resistance and improved safety and smell.
As the aggregate to be used as Component (A) there may be used fibrous substrate or wood. The fibrous substrate is not specifically limited. As the fibrous substrate there may be used inorganic fiber such as glass fiber or organic fiber such as synthetic fiber and natural fiber. In particular, cotton, flax, wool, silk, wood fiber, nylon, etc. are preferred from the standpoint of flexibility and heat insulation of a molded article. Alternatively, inorganic fiber and organic fiber may be used in admixture. Component (A) can be used in the form of yarn or fabric, either woven or nonwoven.
The linear unsaturated polyester to be used as Component (B) comprises an alkylene (having from 2 to 4 carbon atoms) oxide adduct of bisphenol A (average added number of mols: 1 to 10 (The term “average added number of mols” as used herein is meant to indicate average added number of mols per molecule)) in an amount of from 3 to 50 mol % based on the total amount of constituent monomers of Component (B) and preferably has an iodine value of from 70 to 150 from the standpoint of molding properties in high temperatures and strength of molded articles Examples of such an alkylene oxide include ethylene oxide, propylene oxide, and butylene oxide. Preferred among these alkylene oxides are ethylene oxide and propylene oxide. Two or more alkylene oxides may be added. A bisphenol A having ethylene oxide and propylene oxide added thereto is preferred. The average added number of mols of alkylene oxide is preferably from 2 to 5. The content of alkylene oxide adduct of a bisphenol A is preferably from 5 to 40 mol %, more preferably from 8 to 30 mol % from the standpoint of excellence in molding properties, uniformity of molded article and enhancement of strength of molded article at ordinary and high temperatures. The iodine value of Component (B) is more preferably from 75 to 140, even more preferably from 80 to 130 from the standpoint of enhancement of crosslinking density and hence strength of molded article. The iodine value is determined according to JIS K 0070. The softening point of Component (B) is preferably from 80° C. to 130° C.
Other constituent monomers of Component (B) are not specifically limited. Known divalent alcohol components, carboxylic acid components such as divalent carboxylic acid and anhydride and ester thereof, and addition-polymerizable unsaturated group-containing monomers may be used.
The content of these monomers in Component (B) is not limited so far as the foregoing alkylene oxide adduct of bisphenol A is incorporated in an amount of from 3 to 50 mol % based on the total amount of constituent monomers of Component (B).
The ratio of the divalent carboxylic acid component to the divalent alcohol component is preferably from 0.9 to 1.1 mols, particularly from 0.95 to 1.05 mols per mol.
Examples of the divalent alcohol component other than the foregoing alkylene oxide adduct of bisphenol A include ethylene glycol, propylene glycol, 1,6-hexanediol, 1,4-butanediol, bisphenol A, and hydrogenated bisphenol A. Preferred among these divalent alcohol components are ethylene glycol, 1,4-butanediol, and hydrogenated bisphenol A.
Examples of the divalent carboxylic acid component include various dicarboxylic acids, succinic acid substituted by alkyl group having from 1 to 20 carbon atoms or alkenyl group having from 2 to 20 carbon atoms, anhydride and alkyl (having from 1 to 12 carbon atoms) ester thereof, and dimer acids. Preferred among these divalent carboxylic acid components are maleic acid, fumaric acid, terephthalic acid, and succinic acid substituted by alkenyl group having from 2 to 20 carbon atom, such as octenyl succinate anhydride and dodecyl succinate anhydride.
Examples of the addition-polymerizable unsaturated group-containing monomer include fumaric acid, maleic acid, maleic anhydride, and itaconic acid. Preferred among these addition-polymerizable unsaturated group-containing monomers are fumaric acid and maleic anhydride.
The linear unsaturated polyester polyamide to be used as Component (C) comprises an alkylene oxide adduct of bisphenol A in an amount of from 3 to 50 mol % based on the total amount of constituent monomers of Component (C) and preferably has an iodine value of from 70 to 150 from the standpoint of molding properties in high temperatures and strength of molded articles. From the same standpoint of view as for Component (B), the content of the alkylene oxide adduct of bisphenol A is preferably from 5 to 40 mol %, more preferably from 8 to 30 mol %. The iodine value of Component (C) is more preferably from 75 to 140, particular preferably from 80 to 130. Component (C) can be obtained from amine-based monomers in addition to the monomers for use in the production of Component (B). Examples of the amine-based monomer include known vari
Aoki Katsutoshi
Kawabe Kuniyasu
Yamaguchi Takashi
Birch & Stewart Kolasch & Birch, LLP
Kao Corporation
Yoon Tae H.
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