CN101903170A - 复合成形体 - Google Patents
复合成形体 Download PDFInfo
- Publication number
- CN101903170A CN101903170A CN2008801215376A CN200880121537A CN101903170A CN 101903170 A CN101903170 A CN 101903170A CN 2008801215376 A CN2008801215376 A CN 2008801215376A CN 200880121537 A CN200880121537 A CN 200880121537A CN 101903170 A CN101903170 A CN 101903170A
- Authority
- CN
- China
- Prior art keywords
- polybutylene terephthalate
- pbt
- resin
- composite molded
- molded product
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 239000002131 composite material Substances 0.000 title claims abstract description 20
- 229920001707 polybutylene terephthalate Polymers 0.000 claims abstract description 137
- -1 polybutylene terephthalate Polymers 0.000 claims abstract description 86
- 229920005989 resin Polymers 0.000 claims abstract description 72
- 239000011347 resin Substances 0.000 claims abstract description 71
- 229910052751 metal Inorganic materials 0.000 claims abstract description 37
- 239000002184 metal Substances 0.000 claims abstract description 37
- 229920002725 thermoplastic elastomer Polymers 0.000 claims abstract description 21
- QQVIHTHCMHWDBS-UHFFFAOYSA-N perisophthalic acid Natural products OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229920001577 copolymer Polymers 0.000 claims abstract description 17
- 239000000203 mixture Substances 0.000 claims description 23
- 238000012986 modification Methods 0.000 claims description 22
- 230000004048 modification Effects 0.000 claims description 22
- 229920001971 elastomer Polymers 0.000 claims description 14
- 239000000806 elastomer Substances 0.000 claims description 14
- 238000002347 injection Methods 0.000 claims description 9
- 239000007924 injection Substances 0.000 claims description 9
- 229920000728 polyester Polymers 0.000 claims description 9
- 150000001991 dicarboxylic acids Chemical class 0.000 claims description 5
- 229920006124 polyolefin elastomer Polymers 0.000 claims description 5
- 239000003365 glass fiber Substances 0.000 claims description 4
- 238000011282 treatment Methods 0.000 abstract description 3
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 abstract description 2
- 239000011342 resin composition Substances 0.000 abstract 4
- 239000012744 reinforcing agent Substances 0.000 abstract 2
- 239000000805 composite resin Substances 0.000 abstract 1
- 239000002905 metal composite material Substances 0.000 abstract 1
- 238000007788 roughening Methods 0.000 abstract 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 24
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 14
- 150000002148 esters Chemical class 0.000 description 13
- 238000000034 method Methods 0.000 description 13
- 239000000178 monomer Substances 0.000 description 13
- 238000007493 shaping process Methods 0.000 description 13
- 150000001875 compounds Chemical class 0.000 description 11
- 230000006978 adaptation Effects 0.000 description 10
- 239000000463 material Substances 0.000 description 10
- 229920000642 polymer Polymers 0.000 description 10
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 9
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 9
- 229910052782 aluminium Inorganic materials 0.000 description 8
- 239000003795 chemical substances by application Substances 0.000 description 8
- 239000000835 fiber Substances 0.000 description 8
- 238000012545 processing Methods 0.000 description 8
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- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 6
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 5
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- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 125000005907 alkyl ester group Chemical group 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 238000003486 chemical etching Methods 0.000 description 4
- ARCGXLSVLAOJQL-UHFFFAOYSA-N trimellitic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C(C(O)=O)=C1 ARCGXLSVLAOJQL-UHFFFAOYSA-N 0.000 description 4
- 239000004721 Polyphenylene oxide Substances 0.000 description 3
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- 229940106691 bisphenol a Drugs 0.000 description 3
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- 230000003750 conditioning effect Effects 0.000 description 3
- 238000007334 copolymerization reaction Methods 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
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- 239000011256 inorganic filler Substances 0.000 description 3
- 229910003475 inorganic filler Inorganic materials 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
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- 239000003381 stabilizer Substances 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- JTHZUSWLNCPZLX-UHFFFAOYSA-N 6-fluoro-3-methyl-2h-indazole Chemical compound FC1=CC=C2C(C)=NNC2=C1 JTHZUSWLNCPZLX-UHFFFAOYSA-N 0.000 description 2
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
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- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 125000001931 aliphatic group Chemical group 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- QMKYBPDZANOJGF-UHFFFAOYSA-N benzene-1,3,5-tricarboxylic acid Chemical compound OC(=O)C1=CC(C(O)=O)=CC(C(O)=O)=C1 QMKYBPDZANOJGF-UHFFFAOYSA-N 0.000 description 2
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 229920006038 crystalline resin Polymers 0.000 description 2
- 150000002009 diols Chemical class 0.000 description 2
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N diphenyl Chemical compound C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229920006351 engineering plastic Polymers 0.000 description 2
- 229920006226 ethylene-acrylic acid Polymers 0.000 description 2
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 235000011187 glycerol Nutrition 0.000 description 2
- 125000004464 hydroxyphenyl group Chemical group 0.000 description 2
- 239000004973 liquid crystal related substance Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 229920000570 polyether Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- ULWHHBHJGPPBCO-UHFFFAOYSA-N propane-1,1-diol Chemical class CCC(O)O ULWHHBHJGPPBCO-UHFFFAOYSA-N 0.000 description 2
- CYIDZMCFTVVTJO-UHFFFAOYSA-N pyromellitic acid Chemical compound OC(=O)C1=CC(C(O)=O)=C(C(O)=O)C=C1C(O)=O CYIDZMCFTVVTJO-UHFFFAOYSA-N 0.000 description 2
- 238000012797 qualification Methods 0.000 description 2
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 2
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical compound OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- SHKKTLSDGJRCTR-UHFFFAOYSA-N 1,2-dibromoethylbenzene Chemical compound BrCC(Br)C1=CC=CC=C1 SHKKTLSDGJRCTR-UHFFFAOYSA-N 0.000 description 1
- LMAUULKNZLEMGN-UHFFFAOYSA-N 1-ethyl-3,5-dimethylbenzene Chemical compound CCC1=CC(C)=CC(C)=C1 LMAUULKNZLEMGN-UHFFFAOYSA-N 0.000 description 1
- LCJNYCWJKAWZKZ-UHFFFAOYSA-N 1-prop-1-en-2-ylnaphthalene Chemical compound C1=CC=C2C(C(=C)C)=CC=CC2=C1 LCJNYCWJKAWZKZ-UHFFFAOYSA-N 0.000 description 1
- IGGDKDTUCAWDAN-UHFFFAOYSA-N 1-vinylnaphthalene Chemical compound C1=CC=C2C(C=C)=CC=CC2=C1 IGGDKDTUCAWDAN-UHFFFAOYSA-N 0.000 description 1
- SBYMUDUGTIKLCR-UHFFFAOYSA-N 2-chloroethenylbenzene Chemical compound ClC=CC1=CC=CC=C1 SBYMUDUGTIKLCR-UHFFFAOYSA-N 0.000 description 1
- ISPYQTSUDJAMAB-UHFFFAOYSA-N 2-chlorophenol Chemical compound OC1=CC=CC=C1Cl ISPYQTSUDJAMAB-UHFFFAOYSA-N 0.000 description 1
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical class C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 description 1
- JLBJTVDPSNHSKJ-UHFFFAOYSA-N 4-Methylstyrene Chemical compound CC1=CC=C(C=C)C=C1 JLBJTVDPSNHSKJ-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
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- MWGAXDIRSDXWQB-UHFFFAOYSA-N C(CCCCCCCCCCCCCCCCC)C=C(C(=O)OCCCCCCCCCCCCCCCCCC)C.C(C(=C)C)(=O)O Chemical compound C(CCCCCCCCCCCCCCCCC)C=C(C(=O)OCCCCCCCCCCCCCCCCCC)C.C(C(=C)C)(=O)O MWGAXDIRSDXWQB-UHFFFAOYSA-N 0.000 description 1
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- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 1
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 1
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- IAXXETNIOYFMLW-COPLHBTASA-N [(1s,3s,4s)-4,7,7-trimethyl-3-bicyclo[2.2.1]heptanyl] 2-methylprop-2-enoate Chemical compound C1C[C@]2(C)[C@@H](OC(=O)C(=C)C)C[C@H]1C2(C)C IAXXETNIOYFMLW-COPLHBTASA-N 0.000 description 1
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- 239000011777 magnesium Substances 0.000 description 1
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- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
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Abstract
本发明提供具有足够的密合强度,且可在100℃以下的模具温度下成形的聚对苯二甲酸丁二醇酯树脂/金属的复合成形体。具体来说,一种复合成形体,其中,含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物、或含有改性聚对苯二甲酸丁二醇酯树脂和纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物,与表面经过微细凹凸处理的金属(层)附着成一体,所述改性聚对苯二甲酸丁二醇酯树脂由间苯二甲酸成分相对于总二羧酸成分的含有率为3~50摩尔%的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物组成。
Description
技术领域
本发明涉及由金属和聚对苯二甲酸丁二醇酯树脂材料形成的复合成形体。
背景技术
聚对苯二甲酸丁二醇酯树脂由于具有优异的机械特性、电特性、耐热性和耐化学药品性,因此作为工程塑料而被广泛用于汽车部件、电气和电子部件等各种用途中,且也可利用通过聚对苯二甲酸丁二醇酯树脂和金属的嵌件成形(insertmolding)、基体上注塑成型(outsert molding)而制成的复合成形体。为制造这样的树脂和金属的复合成形体,在层压领域中自古以来便对使树脂密合于金属表面的技术进行研究,已对在金属表面形成有微细的凹凸后将热塑性树脂注塑成形而得到密合性的技术进行了各种研究。
例如,日本特开2001-225352号公报中公示了预先对金属表面进行化学蚀刻的方法,日本特开2003-103563号公报公示了用肼等水溶性还原剂对金属表面进行处理的方法。另外,日本特开2006-1216号公报中提出,使用利用铝阳极化处理(alumitetreatment)进行微细凹凸处理得到的铝合金。日本特开2003-170531号公报中提出,对用水溶性胺系化合物水溶液进行表面处理的金属进行注塑成形,进而在用于得到接合强度的聚对苯二甲酸丁二醇酯树脂中配合聚碳酸酯、聚苯乙烯、ABS等非晶态树脂。
然而,这些方法由于使用环境的不同有时会导致耐化学药品性、耐热性不足,另一方面有可能导致韧性变差、尤其是冲击强度降低等。另外已知,对这样的复合成形体而言,模具温度越高则金属和树脂的密合强度越高,但市场中需要在较低的模具温度、特别是可在水温调机中使用的模具温度下进行的成形加工。
发明内容
本发明的目的在于,提供具有充分的密合强度、且可在100℃以下的模具温度下成形的聚对苯二甲酸丁二醇酯树脂/金属的复合成形体。
本发明人等为了解决上述课题而进行了深入研究,结果发现,使用含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物、或含有纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物作为聚对苯二甲酸丁二醇酯树脂材料,将其在表面经过微细凹凸处理的金属表面上进行注塑成形,从而可得到即便在100℃以下的模具温度下仍具有良好的密合强度、可应对市场上的各种使用环境的复合成形体,从而完成了本发明。
即本发明为一种复合成形体,其特征在于,含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物、或含有改性聚对苯二甲酸丁二醇酯树脂和纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物,与表面经过微细凹凸处理的金属(层)附着成一体,其中,所述改性聚对苯二甲酸丁二醇酯树脂由间苯二甲酸成分相对于总二羧酸成分的含有率为3~50摩尔%的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物组成。
根据本发明,通过在表面经过微细凹凸处理的金属的表面上注塑成形特定的聚对苯二甲酸丁二醇酯树脂组合物,在至今进行嵌件成形、基体上注塑成型等的与金属一体注塑成形的领域中,提高了树脂与金属的密合性,因此可简化树脂紧贴金属为目的的金属加工。为此,可得到设计的自由度增加、更为自由的形状的复合成形体。
附图说明
图1是表示密合强度测定用复合成形品的形状的图。
图2是表示测定复合成形品的密合强度的情况的图。
图3是表示气密性试验所用的复合成形品的形状的图。
图4是表示复合成形品的气密性试验的情况的图。
具体实施方式
下面对本发明进行详细说明。
本发明所用的聚对苯二甲酸丁二醇酯树脂材料是,(1)含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物,或(2)含有由间苯二甲酸成分相对于总二羧酸成分的含有率为3~50摩尔%的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物组成的改性聚对苯二甲酸丁二醇酯树脂和纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物。这里,在(1)的方式中,作为聚对苯二甲酸丁二醇酯树脂可单独使用聚对苯二甲酸丁二醇酯树脂,也可组合使用聚对苯二甲酸丁二醇酯树脂和改性聚对苯二甲酸丁二醇酯树脂。
另外,在(2)的方式中,可组合使用改性聚对苯二甲酸丁二醇酯树脂和聚对苯二甲酸丁二醇酯树脂。
特别地,在为了提高生产率而需要缩短成形周期的情况下,有时优选以(1)的方式实施。
本发明所使用的聚对苯二甲酸丁二醇酯树脂是指,由对苯二甲酸或其成酯性衍生物与碳数4的亚烷基二醇或其成酯性衍生物缩聚而得到的聚对苯二甲酸丁二醇酯。另外,聚对苯二甲酸丁二醇酯可为其自身70重量%以上的共聚物。
作为除对苯二甲酸或其成酯性衍生物(低级醇酯等)以外的二元酸成分,可列举出萘二甲酸、己二酸、癸二酸、偏苯三酸、琥珀酸等脂肪族、芳香族多元酸或其成酯性衍生物等,此外,作为除1,4-丁二醇以外的二醇成分,可列举出:常规的亚烷基二醇,例如乙二醇、二乙二醇、丙二醇、三亚甲基二醇、六亚甲基二醇、新戊二醇、环己烷二甲醇等、1,3-辛二醇等低级亚烷基二醇,双酚A、4,4’-二羟基联苯等芳香族醇,双酚A的2摩尔环氧乙烷加成物、双酚A的3摩尔环氧丙烷加成物等环氧烷加成物醇,丙三醇、季戊四醇等多羟基化合物或其成酯性衍生物等。
在本发明中,通过将上述那样的化合物作为单体成分来进行缩聚而生成的聚对苯二甲酸丁二醇酯均可作为本发明的(A)成分使用,可单独使用,也可混合使用两种以上。另外,也可使用属于共聚物的支链聚合物。这里所说的聚对苯二甲酸丁二醇酯支链聚合物是指,将所谓的聚对苯二甲酸丁二醇酯或对苯二甲酸丁二醇酯单体作为主体,添加多官能性化合物,从而形成支链的聚酯。作为这里可使用的多官能性化合物,有均苯三甲酸、偏苯三酸、苯均四酸和它们的醇酯、丙三醇、三羟甲基乙烷、三羟甲基丙烷、季戊四醇等。
另外,本发明所说的改性聚对苯二甲酸丁二醇酯树脂是指,间苯二甲酸成分相对于总二羧酸成分的含有率为3~50摩尔%的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物。这样的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物是在上述聚对苯二甲酸丁二醇酯中将对苯二甲酸或其成酯性衍生物部分的一部分用间苯二甲酸置换而得到的。为保持特性,作为结晶性树脂一般使用将对苯二甲酸成分的3~50摩尔%进行改性得到的树脂,进而当改性比例低于3摩尔%时,在不含有弹性体成分的情况下无法得到充分的与金属的密合性,当改性比例超过50摩尔%时,存在固化速度变慢、生产率变差的情况。
间苯二甲酸可以以可成酯的衍生物、例如二甲酯这样的低级醇酯的形式用于缩聚、作为共聚物成分导入。
另外,当改性比例在上述范围内时,混合二间苯二甲酸含有率不同的两种以上的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物而得到的物质,也可作为本发明的改性聚对苯二甲酸丁二醇酯树脂使用。
使用邻氯苯酚作为溶剂,聚对苯二甲酸丁二醇酯树脂和改性聚对苯二甲酸丁二醇酯树脂在35℃下测定的特性粘度(IV)需要在0.6~1.2dl/g范围内,优选为0.65~1.0dl/g,更优选为0.65~0.8dl/g。当特性粘度低于0.6dl/g时,由于无法充分降低四氢呋喃等以聚对苯二甲酸丁二醇酯树脂为发生源的气体的产生量,成形时会发生外观不良和垢(deposit)附着等,因此不优选。另外,当超过1.2dl/g时,成形时的流动性会变得不良。
接着,热塑性弹性体可缓和由于成形时的金属的线膨胀系数和树脂的收缩率的差异、以及接合后的两种材料的线膨胀的差异而产生的应变及其应力。弹性体种类并没有特别的限定,但由于是向作为工程塑料的聚对苯二甲酸丁二醇酯树脂中添加,加之考虑到耐热性、耐化学药品性等,优选核壳型弹性体、烯烃系弹性体和聚酯系弹性体。
相对于100重量份聚对苯二甲酸丁二醇酯树脂,热塑性弹性体的配合量为3~100重量份,优选为10~50重量份。当热塑性弹性体少于3重量份时,无法得到充分的金属与树脂的密合性的效果,而多于100重量份时,作为结晶性树脂的特性变弱,有可能无法满足作为聚对苯二甲酸丁二醇酯树脂组合物所需的耐热性、耐化学药品性等性能。
核壳型弹性体是由柔软的核层和弹性模量高的壳层形成的弹性体。核层中含有20~70重量%的橡胶状核聚合物。这样的橡胶状核聚合物为由至少一种的丙烯酸C1-C8烷基酯单体(丙烯酸甲酯、丙烯酸乙酯、丙烯酸丙酯、丙烯酸正丁酯、丙烯酸仲丁酯、丙烯酸叔丁酯、丙烯酸戊酯、丙烯酸己酯、丙烯酸庚酯、丙烯酸正辛酯、和丙烯酸-2-乙基己酯)、或由与丙烯酸C1-C8烷基酯单体不同的至少一种烯属不饱和共聚物单体衍生得到的物质,并含有由至少一种交联材料或接枝连接体(graftlinker)衍生得到的单元(例如、丙烯酸烯丙酯这样的不饱和羧酸烯丙基酯)。
丙烯酸核-壳型弹性体的壳层优选与核聚合物接枝的壳聚合物,其含有:至少一种甲基丙烯酸C1-C8烷基酯单体由来的单元,与前述至少一种甲基丙烯酸C1-C8烷基酯单体不同的、至少一种可共聚的烯属不饱和单体由来的单元,其中与前述至少一种甲基丙烯酸C1-C8烷基酯单体不同的、至少一种可共聚的烯属不饱和单体由来的单元含有1~20重量%、优选含有3~15重量%,最优选含有4~8重量%。
作为适宜的可共聚的烯属不饱和单体,可列举出(甲基)丙烯酸C1-C8烷基酯、丙烯腈、甲基丙烯腈、二乙烯基苯、α-甲基苯乙烯、对甲基苯乙烯、氯苯乙烯、乙烯基甲苯、二溴苯乙烯、三溴苯乙烯、乙烯基萘、异丙烯基萘,以及例如丙烯酸癸酯、甲基丙烯酸月桂酯、丙烯酸月桂酯、甲基丙烯酸硬脂基酯(Stearyl Methacrylate)、丙烯酸硬脂基酯(Stearyl Acrylate)、甲基丙烯酸异冰片酯这样的碳数较大的(甲基)丙烯酸C9-C20烷基酯等。此外,(甲基)丙烯酸C1-C8烷基酯单体由于其耐候性的提高而优选,丙烯酸C1-C8烷基酯单体是最优选的。
对于聚烯烃系弹性体,可列举出将聚烯烃作为主链、烯类聚合物作为侧链,用苯乙烯、丙烯腈-苯乙烯共聚物进行接枝而得到的物质。作为用作主链的聚烯烃,可列举出乙烯、丙烯、异戊二烯与脂肪酸乙烯基酯类(醋酸乙烯酯、丙酸乙烯酯等)、丙烯酸酯类(丙烯酸乙酯、丙烯酸丁酯、丙烯酸-2-乙基己酯等丙烯酸C1-C10烷基酯等)等的共聚物。作为这样的烯烃类主链,可列举出例如乙烯-醋酸乙烯酯共聚物、乙烯-丙烯酸C1-C8烷基酯共聚物(乙烯-丙烯酸乙酯共聚物(EEA)、乙烯-丙烯酸丁酯共聚物等)、乙烯-丙烯酸C1-C8烷基酯-(甲基)丙烯酸共聚物、乙烯-苯乙烯共聚物等。
聚酯系弹性体是,含有由短链酯形成的硬链段与由数均分子量约为200~6000的聚醚成分和数均分子量约为200~10000的聚酯成分形成的软链段的共聚物,其硬链段和软链段的比率为20~90(重量%)∶80~10(重量%),优选为30~85(重量%)∶70~15(重量%)。作为构成聚酯硬链段的二羧酸成分,优选对苯二甲酸、间苯二甲酸。另外,作为构成聚酯硬链段的二醇成分,优选碳数2~12的脂肪族或脂环族二醇,即乙二醇、丙二醇、1,4-丁二醇、1,4-丁烯二醇、新戊二醇、1,5-戊二醇、1,6-己二醇、双(对羟基)联苯、双(对羟苯基)甲烷、双(对羟苯基)丙烷等双酚和它们的混合物。
另一方面,作为构成软链段的聚醚成分,尤以聚(环氧烷烃)二醇为适宜的,特别优选聚(氧四亚甲基)二醇。作为构成软链段的聚酯成分,为碳数2~12的脂肪族烃,可适宜地使用同一分子内具有羧酸和醇末端的化合物的缩聚物或环状酯的开环聚合物,优选己内酯聚合物等。
这些热塑性树脂弹性体中,在需要耐水解性、耐热老化性的使用环境下,特别优选使用核壳型弹性体、烯烃系弹性体。
本发明所用的树脂组合物中,为改善拉伸强度等机械强度并抑制成形品的收缩率、提高与金属的密合性而配合纤维状强化剂。
对于纤维状强化剂,含有例如无机纤维[例如玻璃纤维、碳纤维、二氧化硅/氧化铝纤维、氧化锆纤维、金属纤维(例如不锈钢、铝、钛、铜、黄铜等)等]、有机纤维(例如芳香族聚酰胺纤维、氟树脂纤维、液晶性芳香族纤维等),这些可单独使用或组合使用二种以上,但从取得的容易性、成本方面考虑优选使用玻璃纤维。
纤维状强化剂的平均纤维直径并没有特别的限定,例如为1~100μm(例如1~50μm)左右,优选为3~30μm左右。纤维状强化剂的平均纤维长度并没有特别的限定,例如为0.1~20mm左右。
作为纤维状强化剂,通常使用截面为圆形的物质,但从抑制成形品的翘曲变形、防止成形后的密合力降低的观点考虑,也可使用异形截面玻璃。
此外,纤维状强化剂根据需要可利用集束剂或表面处理剂(例如环氧系化合物、丙烯酸系化合物、异氰酸酯系化合物、硅烷系化合物、钛酸酯系化合物等官能性化合物)进行表面处理。纤维状强化剂可利用前述集束剂或表面处理剂预先进行表面处理,也可在制备材料时添加集束剂或表面处理剂进行表面处理。
相对于100重量份聚对苯二甲酸丁二醇酯树脂和/或改性聚对苯二甲酸丁二醇酯树脂,纤维状强化剂的配合量为20~100重量份。当配合量低于20重量份时,与金属的密合性有可能降低,机械特性也不充分。当超过100重量份时,熔融混炼性变差,同时成形性降低,结果导致与金属的密合性也降低,因此不优选。
本发明所用的树脂组合物中,可添加上述纤维状强化剂以外的无机填充剂。作为无机填充剂,有云母、滑石、膨润土等硅酸盐类、碳酸钙、氢氧化镁、勃姆石、硫酸锌、氧化锌、或玻璃片、玻璃珠等,这些可单独使用一种或多种组合使用,只要适量即可缓和与收缩、线膨胀相关的树脂和金属间的差异。
进而,本发明所用的树脂组合物中,根据需要还可添加常用的添加剂,例如抗氧化剂、紫外线吸收剂、耐热稳定剂、耐候稳定剂等稳定剂、润滑剂、脱模剂、着色剂等。
进而,本发明所用的树脂组合物中,只要为不使作为聚对苯二甲酸丁二醇酯树脂的性能降低的程度,还可添加其他的热塑性树脂(例如聚酰胺、丙烯酸酯、聚碳酸酯、聚芳酯、聚乳酸、聚苯乙烯、聚苯醚、AS、ABS等)、热固化性树脂(例如不饱和聚对苯二甲酸丁二醇酯树脂、酚醛树脂、环氧树脂等)。
本发明所使用的聚对苯二甲酸丁二醇酯树脂组合物可为粉粒体混合物、熔融混合物,也可根据需要通过利用常用的方法混合无机填充剂、添加剂等而制备。例如,混合各成分、利用单螺杆或双螺杆的挤出机混合挤出、颗粒化,从而进行制备。
通过使用这样制得的聚对苯二甲酸丁二醇酯树脂组合物和表面经过微细凹凸处理的金属来进行注塑成形可得到复合成形体。
特别地,对于本发明所用的聚对苯二甲酸丁二醇酯树脂组合物,即便在作为成形时的模具温度的、属于通常的水温调机的范围的100℃以下成形,仍可得到良好的密合性,不需要过分提高模具温度。
作为本发明所用的金属表面处理的方法并没有特别的限定,根据金属的材质、形状、要求特性等,可根据需要任意选择。作为用于金属表面的微细凹凸处理,可列举出例如化学蚀刻、用于铝的铝阳极化处理,液体研磨(liquid honing)、喷砂等物理处理,此外还可举出利用化学镀等进行的加工。就化学蚀刻而言,对金属表面用合成化学药品等进行处理的方法由于金属的种类、处理目的的不同而多种多样,现被用于各种产业领域。关于蚀刻的具体例子例如可举出日本特开平10-96088号公报、日本特开平10-56263号公报所记载的方法,并没有特别的限定,可选择任意的现有方法。
另外,铝阳极化处理是用于铝的常规的表面处理法,通过用酸使铝在阳极电解,可形成数十nm~数十μm级别的多孔质。另外,不仅有在表面形成凹部的方法,相反还已知有作为形成凸部的方法的TRI处理等。如上述这样,金属表面的微细凹凸处理通过使用化学方法、或物理方法、电的方法等,或组合使用它们,形成数十nm~数十μm尺寸的凹凸,从而可得到本发明的效果。当凹凸直径过小时,除确认变得困难外,成形时的树脂的进入也变得困难。另外,凹凸直径过大时,由于与树脂的接触面积变小,而难以得到目标的接合强度。
本发明所用的金属种类并没有特别的限定,可利用例如铜、铝、镁、镍、钛、铁等、它们的合金类。另外,也可同样地利用存在于由镍、铬、金等进行镀敷加工的金属表面上的金属。
实施例
通过以下实施例来进一步详细说明本发明,但本发明不限于这些实施例。另外,实施例中的份表示重量份。
实施例1~7、比较例1~3
用The Japan Steel Works,LTD.制造的双螺杆挤出机在料筒温度260℃下对表1所示的组成的聚对苯二甲酸丁二醇酯树脂组合物进行复合而制得。
基于得到的树脂组合物,通过使用Sodech Co.Ltd.制造的注塑成形机而成形得到图1所示的密合强度测定用复合成形品。作为金属,使用对铝(A1050)实施已知化学蚀刻类型的“Taiseiplas co.,ltd.社的NMT处理”而得到的金属。另外,成形在模具温度90℃和140℃的两种条件下进行。对于密合强度,使用图1所示的复合成形品,如图2所示那样,使用将突出部分顶在一定速度的夹具上的方法测定破坏强度。测定使用ORIENTEC Co.,Ltd.制造的TENSILON UTA-50KN-RTC。如表1所示,在模具温度140℃下均得到高密合性,而在模具温度90℃下只有实施例显示出高密合性。
关于气密性试验,通过使经过同样表面处理的铝销(aluminum pin)在模具温度90℃下嵌件成形而得到图3所示的复合成形品,在将其安装于图4所示的夹具后,通过利用压缩空气加压、确认是否在金属与树脂的界面出现漏气来进行评价。压力是通过每0.1Mpa保持1分钟,若确认没有漏气则进一步提高0.1Mpa,直至最大达到0.6Mpa来进行测定。结果如表1所示。
另外,使用的成分的详细情况如下。
·聚对苯二甲酸丁二醇酯树脂:特性粘度0.7dl/g的聚对苯二甲酸丁二醇酯树脂(WinTech Polymer Ltd.制造)
·聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物:用间苯二甲酸使聚对苯二甲酸丁二醇酯骨架中的12.5摩尔%对苯二甲酸改性得到的聚对苯二甲酸丁二醇酯共聚物(特性粘度0.74dl/g、WinTech Polymer Ltd.制造)
·弹性体
a:聚酯系弹性体(TOYOB O CO.,LTD.制造的PELPRENEGP400)
b:核壳型弹性体(Rohm and Haas Company制造的PARALOID EXL-2311)
c:烯烃系弹性体(NOF CORPORATION.制造的MODIPERA5300)
·纤维状强化剂:玻璃纤维(Nippon Electric Glass Co.,Ltd.制造的φ13)
[表1]
Claims (7)
1.一种复合成形体,其特征在于,含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物、或含有改性聚对苯二甲酸丁二醇酯树脂和纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物,与表面经过微细凹凸处理的金属(层)附着成一体,其中,所述改性聚对苯二甲酸丁二醇酯树脂由间苯二甲酸成分相对于总二羧酸成分的含有率为3~50摩尔%的聚对苯二甲酸丁二醇酯/间苯二甲酸共聚物组成。
2.根据权利要求1所述的复合成形体,相对于100重量份聚对苯二甲酸丁二醇酯树脂和/或改性聚对苯二甲酸丁二醇酯树脂,纤维状强化剂的配合量为20~100重量份。
3.根据权利要求1所述的复合成形体,相对于100重量份聚对苯二甲酸丁二醇酯树脂,热塑性弹性体的配合量为3~100重量份。
4.根据权利要求3所述的复合成形体,热塑性弹性体为选自核壳型弹性体、烯烃系弹性体和聚酯系弹性体中的一种以上。
5.根据权利要求1~4任一项所述的复合成形体,纤维状强化剂为玻璃纤维。
6.根据权利要求1~5任一项所述的复合成形体,其通过将表面经过微细凹凸处理的金属预先安装于模具内,在处理面上将含有纤维状强化剂和热塑性弹性体的聚对苯二甲酸丁二醇酯树脂组合物、或将含有纤维状强化剂的改性聚对苯二甲酸丁二醇酯树脂组合物进行注塑成形而得到。
7.根据权利要求6所述的复合成形体,其中复合成形体使用模具温度100℃以下的模具来制成。
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US20100261025A1 (en) | 2010-10-14 |
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KR20100094523A (ko) | 2010-08-26 |
JP5242150B2 (ja) | 2013-07-24 |
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