CN111386302A - 作为用于泡沫材料的基础的pes-ppsu共混物 - Google Patents

作为用于泡沫材料的基础的pes-ppsu共混物 Download PDF

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CN111386302A
CN111386302A CN201880076503.3A CN201880076503A CN111386302A CN 111386302 A CN111386302 A CN 111386302A CN 201880076503 A CN201880076503 A CN 201880076503A CN 111386302 A CN111386302 A CN 111386302A
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composition
foaming
blowing agent
weight
foamed
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C·特拉塞尔
K·伯恩哈德
L·阿尔奥乔
I·雷贝尔
D·罗森
U·朗
T·里希特
M·海克斯
R·范霍恩
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Evonik Operations GmbH
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Abstract

本发明涉及用于制备新型泡沫材料的组合物，它们尤其将良好的阻燃性能与良好的断裂伸长率结合在一起。这些新型泡沫材料是由聚醚砜(PES)和聚亚苯基砜(PPSU)的共混物制备的。

Description

作为用于泡沫材料的基础的PES-PPSU共混物
技术领域
本发明涉及用于制备新型泡沫材料的组合物，它们尤其将良好的阻燃性能与良好的断裂伸长率结合在一起。这些新型泡沫材料是由聚醚砜(PES)和聚亚苯基砜(PPSU)的共混物制备的。
背景技术
PES和PPSU的共混物对于其它技术应用完全是已知的。例如，EP 1 497 376描述了用于在熔融成型、注射模塑、压缩模塑、挤出或吹塑中进行加工的相应的共混物。然而，由这种组合物制备泡沫材料是未知的。
例如，在EP 0 764 461中还描述了得自这样的共混物的多孔膜。这种类型的膜是由水性聚合物组合物经由浇铸方法制备的。
许多工业上使用的泡沫材料要么在高温下的使用过程中有缺点，要么在整体上，并且特别是在这些高温下，具有非最佳的机械性能。另外，只已知非常少的泡沫材料不是易燃的并且因此可例如安装在公路车辆、轨道车辆或飞机的内部空间中。例如，PES泡沫具有差的阻燃效果，而PPSU泡沫例如具有非最佳的断裂强度。
得自PPSU或PES的泡沫材料原则上是已知的，然而它们没有彼此混合。例如，在L.Sorrentino的“Polymeric Foams from High-Performance Thermoplastics(得自高性能热塑性塑料的聚合物泡沫)”,Advances in Polymer Technology,第30卷,第3期,第234-243页,2011(DOI 10.1002/adv)中报道了用于确认使PPSU和/或PES发泡的理想条件的相应研究。
包含PPSU或PSE的共混物同样是已知的，然而在现有技术中提供的细节相当少。例如，这两种聚合物都已经尤其被描述为例如在PS泡沫中作为用量上次要的组分，以影响这些商品材料的性能。相反，包含PPSU或PES作为主要组分的泡沫仅在非常少的说明中找到，例如在以下文献中：
US 4,940,733公开了基于一种共混物的泡沫材料，所述共混物是聚碳酸酯与第二聚合物的共混物，所述第二聚合物除大量其它实例外还可是PES或PPSU。尽管这种类型的泡沫具有高水平的热稳定性，但其阻燃效果不是特别好。关于机械性能也没有提供任何细节。
WO 2015/097058描述了基于PPSU或PES的泡沫材料，其包含至少10重量％的聚烯烃。该相分离的聚烯烃在此主要起到成核剂的作用。在此，尽管获得了更均匀的孔，但阻燃性能或机械性能(例如断裂伸长率)没有被有利影响。实际上，由于相分离甚至可能预期较差的断裂伸长率。阻燃性也可能由于掺混聚烯烃组分而预期变差。
发明内容
要解决的技术问题
鉴于现有技术，本发明要解决的问题是提供一种用于制备新型泡沫材料的组合物。所得的泡沫材料在此应表现出以下性能的良好结合：在高温下的可应用性、良好的机械性能(特别是关于断裂伸长率)和对于在车辆和飞机构造中的许多应用至少充分的阻燃效果。
尤其是，所述泡沫材料在此应在最高至120℃，优选最高至150℃的环境温度的应用范围内也可使用较长时间。
所述泡沫材料还应可以由待提供的组合物经由各种各样的方法并以非常多样的形式实现。
其它未明确说明的要解决的问题可从本文的说明书、权利要求书或实施例中得出，而在此不为了这个目的对其明确叙述。
解决方案
所述问题通过提供一种新型组合物得到解决，所述组合物用于制备热稳定的低可燃性泡沫材料。这种本发明的用于制备泡沫材料的组合物的特征在于，它含有60至98重量％的PES和PPSU的混合物作为主要成分，所述混合物中PES和PPSU的比例在1:9和9:1之间，优选在1:1和8.5:1之间。
这种组合物进一步包含0.5至10重量％的发泡剂。其尤其可进一步含有0至10重量％的添加剂和0至20重量％的第三聚合物组分。
所述组合物更优选由90至95重量％的PES和PPSU以在1:1和8:1之间的比例的混合物、1至9重量％的发泡剂和1至5重量％的添加剂组成。
所述添加剂可特别是阻燃剂、增塑剂、颜料、UV稳定剂、成核剂、抗冲改性剂、粘合促进剂、流变学改性剂、扩链剂、纤维和/或纳米粒子。
使用的阻燃剂通常是磷化合物，特别是磷酸酯(盐)、膦或亚磷酸酯(盐)。合适的UV稳定剂和/或UV吸收剂是本领域技术人员公知的。为了这个目的，通常使用HALS化合物、Tiuvine或三唑。使用的抗冲改性剂通常是包含弹性体和/或软相的聚合物粒子。这些聚合物粒子经常是核-(壳-)壳粒子，其具有外壳，所述外壳本身最多轻度交联并且作为纯聚合物会表现出与所述PES和PPSU的共混物具有至少最小的混容性。原则上，任何已知的颜料可用作颜料。当然，尤其在较大量的情况下需要对于对发泡操作的影响进行测试，如所有以高于0.1重量％的较大量使用的其它添加剂的情况中那样。这对于本领域技术人员而言可以较小复杂性和成本实施。
合适的增塑剂、流变学改性剂和扩链剂是本领域技术人员由PES、PPSU或这两者的共混物制备片材、膜或模制品中公知的，并且可相应地在较小成本和复杂性下转用到由根据本发明的组合物制备泡沫上。
所述纤维通常是已知的可添加到聚合物组合物中的纤维材料。在本发明的一个特别合适的实施方案中，所述纤维是PES纤维、PPSU纤维或共混物纤维，后者得自PES和PPSU。
纳米粒子，其可例如以小管、小板、棒、球形式或其它已知形式存在，通常是无机材料。它们可以在同一时间在最终的泡沫中发挥多种功能。例如，这些粒子在发泡操作中部分地起到成核剂的作用。所述粒子可进一步影响所述泡沫的机械性能以及(气体)扩散性能。所述粒子还进一步对低可燃性做出额外贡献。
除了列举的纳米粒子外，还可以添加微米粒子或较低混容性的相分离的聚合物作为成核剂。在此，在考虑组成时，所描述的聚合物必须与其它成核剂分开来看，因为后者主要对所述泡沫的机械性能、对所述组合物的熔体粘度产生影响，并且因此对发泡条件产生影响。相分离的聚合物作为成核剂的额外作用是这种组分的额外希望的效果，但在这种情况下不是主要效果。因此，这些额外聚合物在总计中如进一步上文所述与其余添加剂分开考虑。
所述额外聚合物可例如是聚酰胺，聚烯烃，特别是PP，PEEK，聚酯，特别是PET，其它硫基聚合物，例如PSU，聚醚酰亚胺或聚甲基丙烯酰亚胺。
发泡剂的选择是相对自由的，并且对于本领域技术人员而言是特别由选择的发泡方法和发泡温度所确定的。合适的例如是醇，例如异丙醇或丁醇，酮，例如丙酮或甲乙酮，烷烃，例如异丁烷或正丁烷、异戊烷或正戊烷、己烷、庚烷或辛烷，烯烃，例如戊烯、己烯、庚烯或辛烯，CO2，N2，水，醚，例如乙醚，醛，例如甲醛或丙醛，氟(氯)烃，化学发泡剂或这些物质中的两种或更多种的混合物。
化学发泡剂是较不挥发或完全不挥发的物质，其在发泡条件下经历化学分解并在此时形成实际的发泡剂。叔丁醇是它的一个非常简单的实例，它在发泡条件下形成异丁烯和水。其它实例是NaHCO3、柠檬酸或柠檬酸衍生物、偶氮二甲酰胺(ADC)和/或基于其的化合物，甲苯磺酰肼(TSH)，氧代双(苯磺酰肼)(OBSH)或5-苯基四唑(5-PT)。
优选用作发泡剂的是CO2、N2或这两者的混合物。
不仅所述组合物，而且自然还有由本发明的组合物制备的泡沫材料也是本发明的组成部分。
本发明还进一步提供使本发明的组合物发泡的方法。在此，使所述组合物在150和250℃之间的温度下和在0.1和2巴之间的压力下发泡。发泡优选在180和230℃之间的温度下在标准压力气氛中进行。
原则上，使聚合物组合物发泡的多种方法是本领域技术人员已知的，其特别是在用于热塑性泡沫的方法方面可用于本发明的组合物。然而，存在一些特别优选的备选方案。
在第一优选变体中，将还没有发泡剂的组合物在高压釜中在20和120℃之间的温度下和在30和100巴之间的压力下与所述发泡剂混合，并随后通过降低压力和将温度升高到发泡温度使其在所述高压釜中发泡。备选地，将与所述发泡剂混合的组合物在所述高压釜中冷却并在冷却后移出。然后可将这种组合物随后通过加热到发泡温度而发泡。这也可例如在进一步的成型下进行或与诸如插入件或面层的其它元件组合进行。
在所述方法的第二变体中，将含有所述发泡剂的组合物在挤出机中加热。
在所述方法的第三变体中，将没有发泡剂的组合物在挤出机中加热并在所述挤出机中与所述发泡剂混合，优选与CO2和/或N2混合。
根据所述第二或第三变体将所述组合物从所述挤出机中排出的情况下，下文中给出了进一步的实施方案。例如，所述组合物可经由宽缝模头或一些其它成型模头离开所述挤出机，并在此时发泡。这个变体可例如与直接随后的共挤出或层合组合，使得面层被直接施加到从宽缝模头形成的泡沫板或片材上。
在所述第二或第三变体的第二个实施方案中，所述组合物当从挤出机中出来时发泡，并且在此借助造粒机产生粒子泡沫。通常，在此，所述造粒机如此接近于所述模头的出口点安装，使得已经分离出的粒子在形成后直接发泡。
在所述第二或第三变体的第三个实施方案中，最后，可将离开所述挤出机的组合物引入泡沫喷射设备(Schaumspritzvorrichtung)中。在该设备中，然后直接在成型的同时进行发泡。
第四个备选的实施方案的特征在于将从挤出机中出来的组合物引入水下造粒机，在其中存在使得发泡被阻止的温度和压力的组合。在这样的程序中获得的装载有发泡剂的粒料然后可被发泡，例如热发泡。
根据本发明的泡沫材料和/或通过本发明的方法制备的泡沫材料可用于许多用途。所述泡沫材料在此优选用于车辆构造，例如公路车辆、轨道车辆、水路船舶、航天器或飞机的构造。由于低可燃性，本发明的泡沫材料还可更特别地被安装在这些车辆的内部空间。其它应用领域包括例如电气和电子工业，风力发电系统的构造或机械工程。
本发明的泡沫材料优选具有的发泡度为使得与纯共混物相比密度降低在1和98％之间，优选在50和97％之间，更优选在70和95％之间。泡沫的密度优选在20和1000kg/m3，优选40和250kg/m3之间。

Claims (14)

1.用于制备泡沫材料的组合物，其特征在于这种组合物含有60至98重量％的PES和PPSU以在1:9和9:1之间的比例的混合物、0.5至10重量％的发泡剂、0至10重量％的添加剂和0至20重量％的第三聚合物组分。
2.根据权利要求1的组合物，其特征在于PES和PPSU以在1:1和8.5:1之间的比例存在。
3.根据权利要求1或2的组合物，其特征在于所述添加剂是阻燃剂、增塑剂、颜料、UV稳定剂、成核剂、抗冲改性剂、粘合促进剂、流变学改性剂、扩链剂、纤维和/或纳米粒子。
4.根据权利要求1至3中至少一项的组合物，其特征在于所述发泡剂是醇、酮、烷烃、烯烃、CO2、N2、水、醚、醛、化学发泡剂或这些物质中的两种或更多种的混合物。
5.根据权利要求1至4中至少一项的组合物，其特征在于所述组合物由90至95重量％的PES和PPSU以在1:1和8:1之间的比例的混合物、1至9重量％的发泡剂和1至5重量％的添加剂组成。
6.通过使根据权利要求1至5中至少一项的组合物发泡获得的泡沫材料。
7.使根据权利要求1至5中至少一项的组合物发泡的方法，其特征在于使所述组合物在150℃和250℃之间的温度下和在0.1和2巴之间的压力下发泡。
8.根据权利要求7的方法，其特征在于使所述组合物在180和230℃之间的温度下在标准压力气氛中发泡。
9.根据权利要求7或8的方法，其特征在于将没有发泡剂的组合物在高压釜中在20和120℃之间的温度下和在30和100巴之间的压力下与所述发泡剂混合，并随后通过在所述高压釜中降低压力和将温度升高到发泡温度而发泡，或者在所述高压釜中冷却并从高压釜中移出后通过加热到发泡温度而发泡。
10.根据权利要求7或8的方法，其特征在于将所述组合物在挤出机中加热。
11.根据权利要求7或8的方法，其特征在于将没有发泡剂的组合物在挤出机中加热并与所述发泡剂混合。
12.根据权利要求10或11的方法，其特征在于所述组合物经由宽缝模头或其它成型模头离开所述挤出机并在此时发泡。
13.根据权利要求10或11的方法，其特征在于所述组合物在从所述挤出机出来时引入到水下造粒机中，在其中存在使得发泡被阻止的温度和压力的组合，和特征在于获得了装载有发泡剂的粒料，其随后被发泡。
14.根据权利要求10或11的方法，其特征在于所述组合物从所述挤出机引入到泡沫喷射设备中，并在那里在成型的同时被发泡。
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