Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2001-07-17
2003-08-12
Mullis, Jeffrey (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S508000, C524S514000, C524S515000, C524S522000, C524S528000
Reexamination Certificate
active
06605665
ABSTRACT:
The invention relates to fiber-reinforced molding compositions, moldings and composites made therefrom, and also to the use of the molding compositions, moldings and composites
Moldings made from polymeric materials used in particular in the interior of motor vehicles have to meet high requirements, particularly for their mechanical properties, surface properties, aging performance and also odor performance. Various polymeric materials are currently used to produce moldings for interior applications in motor vehicles.
One material used is glass-fiber-reinforced ABS/PC (a polymer blend made from acrylonitrile/butadiene/styrene copolymer and polycarbonate). However, this material has inadequate UV resistance, poor flowability, poor heat-aging performance (toughness and elongation at break after heat aging), disadvantageous surface properties, in particular foam adhesion, poor foam adhesion and exhibits migration of the glass fibers out of the material, and in particular has poor odor performance. For the purposes of the present invention, odor performance relates to the tendency of materials to give off volatile constituents with a detectable odor after a given period of storage under particular temperature and humidity conditions.
Another material used is glass-fiber-reinforced, impact-modified SMA (styrene-maleic anhydride copolymer). SMA, too, has inadequate surface properties, poor heat-aging resistance, and in particular adverse heat resistance and poor odor performance.
Another material which may be considered for producing moldings for automotive interiors is PPE/HIPS GF (a polymer blend made from polyphenylene ether and high-impact polystyrene, and also glass fibers). This material likewise has poor flowability, poor surface properties, in particular the migration of the glass fibers out of the material, giving a rough surface, poor UV resistance, poor heat aging and, finally, poor odor performance.
Another material suitable for interior applications in motor vehicles 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 poor stiffness, poor foam adhesion and poor coatability.
The abovementioned materials, other than mineral-reinforced PP, also have poor heat resistance, expressed in terms of a low Vicat B softening point (Vicat B <130° C.). However, good heat resistance and heat-aging resistance are essential in the materials used, since the temperature in motor vehicle interiors can rise considerably, in particular as a result of insolation.
DE 41 23 041 A1 relates to a thermoplastic molding composition comprising, as principal component and in addition to other components, from 40 to 90 parts by weight of a thermoplastic aromatic polycarbonate.
DE 44 36 776 A1 relates to a thermoplastic polycarbonate molding composition with from 50 to 95% by weight of a thermoplastic aromatic polycarbonate as principal constituent.
CA-JP 03-263453 A relates to a solvent-resistant thermoplastic molding composition made essentially from polycarbonate and polybutylene terephthalate, with steel-fiber reinforcement.
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. The molding compositions are to have an advantageous property profile in relation to their mechanical, optical and sensory properties, and in particular have good heat resistance and heat-aging resistance and good emission performance and/or odor performance. The molding compositions should moreover have a very low density. The low density is advantageous particularly with regard to saving fuel in motor vehicles. Laser-marking, preferably laser-inscription, of the surface of the molding composition is also desirable. This permits the surface to be designed in a manner which is technically simple and highly precise. The molding compositions should, in addition, have very low emission of volatile constituents, so that the novel molding compositions can be used to produce moldings which have preferably metallized, heat-resistant surfaces and are particularly used in headlamps. The surfaces of the moldings made from the novel molding compositions should also give good adhesion to foams.
We have found that this object is achieved by a fiber-reinforced molding composition comprising, based on the total of components A to F, and, if used, G to I, which in total give 100% by weight,
a) as component A, from 1 to 96,86% by weight of at least one polycondensate,
b) as component B, from 1 to 12% 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 1 to 12% 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 1 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 0.01 to 2% by weight of a carbon black,
g) as component G, from 0 to 12% 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 0.1 to 10% by weight of conventional additives, such as UV stabilizers, pigments, oxidation retarders, lubricants and mold-release agents.
The component A present in the novel molding composition is the balancing constituent of the molding composition making up 100% by weight, i.e. in the present makeup of the molding composition up to 96.86% by weight, preferably from 20 to 75% by weight, particularly preferably from 30 to 60% by weight, of a preferably fusible polycondensate which is preferably not a polycarbonate, preferably of a polyester and particularly preferably of an aromatic polyester. The polycondensates present in the novel molding compositions are known per se.
Component A preferably has a viscosity number of from 90 to 160, particularly preferably from 100 to 140.
The polyester 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. Mention may be made here, merely as examples, of naphthalene dicarboxylic 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 and 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(hydroxy-methyl)cyclohexane, bisphenol A, neopentyl glycol, mixtures of these diols or else ester-forming derivatives of the same.
Other preferred aromatic polyesters are polytrimethylene terephthalate (PTT) and in particular polybutylene terephthalate (PBT), formed exclusively from terephthalic acid with the corresponding diols 1,2-ethanediol, 1,3-propanediol and 1,4-butanediol. Some or all of the aromatic polyesters used may be in the form of recycled polyester materials, such as PET regrind from bottle material or from bottle production waste.
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 100% by weight, of polybutylene terephthalate, and
a2) from 0 to 40% by weight, preferably from 0 to 20% by weight, particularly preferably from 0 to 10% by weight, of another polycondensate.
In another embodiment of the invention the molding composition comprises no PET. Preference is moreover given to molding compositions in which compo
Berz Stephan
Fischer Michael
Ginss Christophe
Knoll Manfred
BASF - Aktiengesellschaft
Keil & Weinkauf
Mullis Jeffrey
LandOfFree
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