Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From phenol – phenol ether – or inorganic phenolate
Reexamination Certificate
2001-10-18
2002-11-12
Boykin, Terressa M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From phenol, phenol ether, or inorganic phenolate
C528S196000, C525S067000
Reexamination Certificate
active
06479617
ABSTRACT:
The invention relates to fiber-reinforced molding compositions, moldings and composites made therefrom, and to recycled materials made from these, and also to the use of the molding compositions, moldings, composites and recycled materials.
Moldings made from polymeric materials and used in particular in motor vehicle interiors have to meet high requirements, especially with respect to their mechanical properties, their surface properties, their aging performance, and also their odor and emission performance. A variety of polymeric materials has hitherto been used to produce moldings for interior applications in motor vehicles.
Another material used is glass-fiber-reinforced ABS/PC (a polymer blend made from acrylonitrile-butadiene-styrene copolymer and polycarbonate). However, this material has unsatisfactory UV resistance, poor flowability, poor heat-aging performance (toughness and elongation at break after heat-aging), disadvantageous surface properties, poor foam adhesion and also in particular poor odor performance. For the purposes of the present invention, odor performance is the tendency of materials, after a specified duration of aging under particular temperature and climatic conditions, to give off volatile constituents which have a discernible odor.
Another material used is glass-fiber-reinforced, impact-modified SMA (styrene-maleic anhydride copolymer). SMA, too, has unsatisfactory surface properties, poor heat-aging resistance, and in particular low heat resistance and poor odor performance.
Another material used to produce moldings for motor vehicle interiors is PPE/HIPS GF (a polymer blend made from polyphenylene ether and high-impact polystyrene and also glass fibers). Disadvantages of this material are poor flowability, poor UV resistance and heat-aging resistance, and also poor odor performance.
Another material suitable for motor vehicle interior applications is PP/mineral/EPDM. This is a polymer blend composed of polypropylene, a mineral filler and an ethylene-propylene-diene terpolymer. This material, too, has low stiffness, poor foam adhesion and poor paintability.
Other than mineral-reinforced PP, the abovementioned materials also have poor heat resistance, apparent in a low Vicat B softening point (Vicat B<130° C.). Good heat resistance and heat-aging resistance of the materials used is, however, desirable since the temperature of the motor vehicle interior can rise considerably, especially when exposed to solar radiation.
It is an object of the present invention to provide molding compositions suitable for producing moldings which are used in the interior of motor vehicles and have an advantageous property profile in terms of their mechanical, optical and sensory properties, and also in particular have good heat resistance and heat-aging resistance, and good emission performance and/or odor performance. The molding compositions should also have a very low density. The low density is particularly advantageous with respect to fuel saving in motor vehicles. Laser marking is also desirable, preferably laser inscription of the surface of the molding composition. This allows the surface to be modified in a way which is industrially simple and very precise.
We have found that this object is achieved by a fiber-reinforced molding composition comprising, based on the total of components A to I, which overall is 100% by weight,
a) as component A, at least one polycondensate as a constituent which brings the total to 100% by weight of the molding composition,
b) as component B, from 1 to 15% by weight of at least one particulate graft copolymer whose soft phase has a glass transition temperature below 0° C. and whose median particle size is from 50 to 1000 nm,
c) as component C, from 0 to 15% by weight of at least one copolymer made from the following monomers
c1) as component C1, from 50 to 90% by weight of at least one vinylaromatic monomer, and
c2) as component C2, from 10 to 50% by weight of acrylonitrile and/or methacrylonitrile, based in each case on component C,
d) as component D, from 0 to 20% by weight of fibers,
e) as component E, from 0.01 to 15% by weight of a polycarbonate,
f) as component F, from 0 to 2% by weight of a carbon black,
g) as component G, from 0.01 to 15% by weight of a polymer other than component B,
h) as component H, from 0 to 20% by weight of a polyester other than component A,
i) as component I, from 0 to 10% by weight of customary additives, such as UV stabilizers, pigments, oxidation retarders—lubricants and mold-release agents.
In one embodiment of the novel fiber-reinforced molding composition no component C is present. In another preferred embodiment of the fiber-reinforced molding composition no component D is present. Another preferred embodiment of the fiber-reinforced molding composition comprises no component F. Yet another preferred embodiment of the fiber-reinforced molding composition comprises no component H. In another embodiment of the fiber-reinforced molding composition none of components C, D, F and H are present. Another preferred embodiment of the novel molding composition comprises at least component C, but not components D, F and H.
As component A, the constituent which makes up the remainder to give 100% by weight of the molding composition, the novel molding composition preferably comprises from 20 to 75% by weight, particularly preferably from 30 to 60% by weight, of a preferably fusible polycondensate, preferably a polyester and particularly preferably an aromatic polyester. The polycondensate present in the novel molding compositions are known per se. The polycondensates preferably have a viscosity number of from 40 to 135, with preference from 70 to 130 and particularly preferably from 80 to 110.
The polyester polycondensates may preferably be prepared by reacting terephthalic acid, its esters or other ester-forming derivatives, with 1,4-butanediol, 1,3-propanediol or, respectively, 1,2-ethanediol, in a manner known per se.
Up to 20 mol % of the terephthalic acid may be replaced by other dicarboxylic acids. Those which may be mentioned, merely as examples, are naphthalenedicarboxylic acids, isophthalic acid, adipic acid, azelaic acid, sebacic acid, dodecanedioic acid and cyclohexanedicarboxylic acids, mixtures of these carboxylic acids, and ester-forming derivatives of the same.
Up to 20 mol % of the dihydroxy compounds 1,4-butanediol, 1,3-propanediol or, respectively, 1,2-ethanediol may also be replaced by other dihydroxy compounds, e.g. 1,6-hexanediol, 1,4-hexanediol, 1,4-cyclohexanediol, 1,4-di(hydroxymethyl)cyclohexane, bisphenol A, neopentyl glycol, mixtures of these diols, or also ester-forming derivatives of the same.
Other preferred aromatic polyesters are polytrimethylene terephthalate (PTT) and in particular polybutylene terephthalate (PBT), whose formation involves exclusively terephthalic acid and the appropriate diols 1,2-ethanediol, 1,3-propanediol and 1,4-butanediol. Some or all of the aromatic polyesters may be used in the form of recycled polyester materials, such as PET regrind from bottle material (post-consumer) or from wastes from bottle production (post-industrial).
In a particularly preferred embodiment component A is composed of
a1) from 60 to 100% by weight, preferably from 80 to 100% by weight, particularly preferably from 90 to 99.9% by weight of polybutylene terephthalate (A1) and
a2) from 0 to 40% by weight, preferably from 0 to 20%, particularly preferably from 0.1 to 10% by weight, of another polycondensate.
If component A has constituent A1 it is particularly preferable for A1 to have a viscosity number of from 60 to 135, preferably from 70 to 130, particularly preferably from 80 to 100 and with particular preference from 85 to 95.
In another embodiment of the invention the molding composition comprises no PET. Preference is moreover given to molding compositions in which component A is PET-free.
The novel molding composition comprises, as component B, from 1 to 15% by weight, preferably from 4 to 10% by weight, particularly preferably from 5 to 8% by weight, of at
Blinne Gerd
Fischer Michael
Mc Kee Graham Edmund
BASF - Aktiengesellschaft
Boykin Terressa M.
Keil & Weinkauf
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