EP0935638A1 - Process for preparing compositions based on thermoplastic polymers and polyamides - Google Patents

Abstract

The invention concerns a process for preparing compositions containing at least one thermoplastic polymer A and at least one polyamide B by dissolving the thermoplastic polymer A in at least one lactam b and optionally further polyamide-forming monomers b, and subsequent polymerization of the monomers b. The monomers b are polymerized in the presence of between 0.001 and 5 wt % water, relative to the monomers b.

Description

Process for the preparation of compositions based on thermoplastic polymers and polyamides

description

The present invention relates to a new process for the preparation of compositions comprising at least one thermoplastic polymer A and at least one polyamide B by dissolving the thermoplastic polymer A in at least one lactam b and, if desired, further polyamide-forming monomers b and then polymerizing the monomers b. Furthermore, the present invention relates to the compositions produced by the process, their use and polymer mixtures, moldings, films or fibers which contain these compositions.

Polyamides can be produced in many different ways. One way to get polyamides is by ring-opening hydrolytic polymerization of lactams. A variant of this method, which can also be carried out on an industrial scale, is described, for example, in DE-A 43 21 683.

Mixtures of polyamides with amorphous plastics such as polyarylene ether sulfones or polyetherimides are known. The mechanical properties of the mixtures are the better, the more finely divided the amorphous polymers are dispersed in the polyamide.

In order to produce blends of this type, US Pat. No. 3,729,527 states, inter alia, that ε-caprolactam can be polymerized in the presence of polyarylene ether sulfone. DE-A 41 02 996 also suggests polymerizing lactams in the presence of amorphous polymers such as polysulfones, polyphenylene ethers, polyetherimides, polyamideimides or styrene copolymers in order to produce polymer alloys. The polymerization is initiated using strong bases.

If the polymeric blend components are mixed in the melt, for example in an extruder, compatibilizers are generally added to them. According to EP-A 374 988, Mc Grath et al. Poly. Prepr. 14, 1032 (1973) or Corning et al. , Makromol. Chem. Macromol. Symp. 75, 159 (1993) come as compatibilizers copolymers from polyamide and polyarylene ether sulfone segments. into consideration, which are prepared by dissolving the polyarylene ether sulfone in a lactam melt and the lactam is polymerized in the presence of a strong base and with the exclusion of water.

Studies on the anionic polymerization of lactams in the presence of polyetherimides or polysulfones in an extruder are e.g. also by VanBuskirk et al. Polym, Prepr. 29 (1), 557 (1988).

The processes mentioned have the disadvantage that the polymer chains of the thermoplastic polymers are broken down by attacking the anions present in the reaction mixture. In addition, anionic polymerization requires special technical measures to control the degree of polymerization, since the reaction generally proceeds very quickly and there is a sharp increase in viscosity within a short time. Consequently, products with a defined structure, i.e. Chain length or viscosity, if at all, can only be obtained with difficulty. The products also contain catalyst residues and degradation or by-products that can often no longer be removed. If the polymerization is carried out in an extruder, complete conversion can often not be achieved and the end product therefore still contains residual monomers. Furthermore, only dark ones, e.g. brown, received products.

Schnablegger et al., Acta Polym. 46,307, 1995 describe the reaction of ε-caprolactam with polyarylene ether sulfones which contain aminophenyl end groups. The amino groups react with the ε-caprolactam to open the ring and thus initiate the polymerization reaction. The reaction is carried out in the absence of water and phosphoric acid can be used as a catalyst. The disadvantage of this process is that polyarylene ether sulfones with two aminophenyl end groups per polymer chain can only be prepared in a costly, pure manner.

It was an object of the present invention to provide a new process by means of which finely dispersed compositions based on a wide variety of thermoplastics and polyamides are accessible, in which the thermoplastic polymers are not or only insignificantly degraded. The new method should also allow good control of the viscosity of the compositions to be produced. In addition, the new process should be used to obtain products with good mechanical properties which are either obtained during manufacture or are easy to clean. Accordingly, a process for the preparation of compositions containing at least one thermoplastic polymer A and at least one polyamide B was achieved by dissolving the thermoplastic polymer A in at least one lactam b and, if desired, further polyamide-forming monomers b and subsequent

Polymerization of the monomers b, in which the monomers b are polymerized in the presence of 0.001 to 5% by weight of water, based on the monomers b.

Suitable thermoplastic polymers A are all polymers which dissolve in the lactams or their mixtures with other polyamide-forming monomers b and do not impair their polymerization. According to the invention, dissolving means the production of a melt that appears clear to the viewer, i.e. the polymers A can be physically dissolved or finely dispersed. Suitable amorphous polymers A include polyarylene ethers such as polyarylene ether sulfones or polyphenylene ethers, polyetherimides, polyamideimides, polystyrene or styrene copolymers such as styrene / acrylonitrile copolymers, styrene / diene copolymers, graft copolymers based on diene or acrylate rubbers such as so-called ABS (acrylonitrile / styrene / acrylonitrile / , ASA (acrylonitrile / styrene / acrylate) or AES (acrylonitrile / ethylene / styrene) or other ethylene copolymers. Mixtures of different polymers A can also be dissolved.

Suitable polyarylene ethers are, in particular, those of the general formula (I).

The variables t and q mentioned in the general formula I can each assume the value 0, 1, 2 or 3. T, Q and Z can be independently the same or different. They can be a chemical bond or a group selected from -O-, -S0 ₂ -, -S-, c = 0, -N = N- and S = 0. In addition, T, Q and Z can also represent a group of the general formula -R ^a C = CR ^b - or -CR ^c R ^d -, where R ^a and R ^{b are} each hydrogen or Ci to CiQ-alkyl groups, R ^c and R ^{d in} each case hydrogen, C 1 ~ to C 1 -C 6 -alkyl, such as methyl, ethyl, n-propyl, i-propyl, t-butyl, n-hexyl, C 1 to C ₁ -alkoxy such as methoxy, ethoxy, n-propoxy, i- Propoxy, n-butoxy or C ₆ - to Ciβ-aryl groups such as phenyl or naphthyl mean. R ^c and R ^d can also be linked together with the carbon atom to which they are attached to form a cycloalkyl ring having 4 to 7 carbon atoms. Among them, cyclopentyl or cyclohexyl are preferred. The cycloalkyl rings can be unsubstituted or with one or more, preferably two or three, Ci to C ₆ alkyl groups. Methyl is one of the preferred substituents on the cycloalkyl rings. Polyarylene ethers in which T, Q and Z are -0-, -S0 ₂ -, C = 0, a chemical bond or a group of the formula -CR ^c R ^{d are} preferably used. The preferred radicals R ^c and R ^d include hydrogen and methyl. At least one of the groups T, Q and Z means -S0 - or C = 0. If the two variables t and q are 0, then Z is either -S0 ₂ - or C = 0, preferably -S0 ₂ -. Ar and Ar ¹ are C _ß to Ciβ aryl groups, such as 1, 5-naphthyl, 1, 6 -naphthyl, 2, 7 -naphthyl, 1,5-anthryl, 9, 10-anthryl, 2 , 6-anthryl, 2,7-anthryl or biphenyl, especially phenyl. These aryl groups are preferably not substituted. However, they can have one or more, for example two, substituents. As substituents come C 1 -C 1 -alkyl, such as methyl, ethyl, n-propyl, i-propyl, t-butyl, n-hexyl, C 1 -C ₈ -aryl, such as phenyl or naphthyl, C 1 ~ to C 1 -C Alkoxy radicals such as methoxy, ethoxy, n-propoxy, i-propoxy, n-butoxy and halogen atoms into consideration. Preferred substituents include methyl, phenyl, methoxy and chlorine.

Some suitable recurring units are listed below:

CF ₃

£ ~ e V-sc - / -o-x sorl soa- / W (Il3)

CH ₃

0 0

Polyarylene ethers with repeat units (I (), (I ₂ ) or de) are very particularly preferred. These include, for example, polyarylene ethers with 0 to 100 mol% of repeating units (Iχ) and 0 to 100 mol% of repeating units (I ₂ ).

The polyarylene ethers can also be copolymers or block copolymers in which polyarylene ether segments and segments of other thermoplastic polymers such as polyesters, aromatic polycarbonates, polyester carbonates, polysiloxanes, polyimides or polyetherimides are present. The molecular weights (number average) of the block or graft arms in the copolymers are generally in the range from 1,000 to 30,000 g / mol. The blocks of different structures can be arranged alternately or statistically. The proportion by weight of the polyarylene ethers in the copolymers or block copolymers is generally at least 10% by weight. The proportion by weight of the polyarylene ethers can be up to 45 97% by weight. Co or block copolymers with a weight fraction of polyarylene ether of up to 90% by weight are preferred. Co or block copolymers with 20 to 80% by weight polyarylene ether are particularly preferred.

Also suitable as polyarylene ethers are those which are modified with monomers containing acid or anhydride groups. Such polyarylene ethers can e.g. starting from the corresponding monomers containing acid and / or anhydride groups. They can also be obtained by grafting these monomers onto the polyarylene ether chain. Suitable acid groups include carboxylic, sulfonic and

Phosphonic acid groups. Polyarylene ether sulfones which contain acidic groups, either sequentially or randomly distributed over the polymer chain, are particularly preferred, the acidic groups e.g. can be bound to the arylene radicals or alkylene intermediate members. For example, polyarylene ether sulfones come into consideration which are modified with fumaric acid, maleic acid, maleic anhydride or particularly preferably 4, 4'-dihydroxyvaleric acid. Examples of such polyarylene ether sulfones are e.g. can be found in EP-A 185 237.

Mixtures of two or more different polyarylene ether sulfones can also be used.

In general, the polyarylene ethers have average molecular weights M _n (number average) in the range from 5,000 to 60,000 g / mol and relative viscosities from 0.20 to 0.95 dl / g. Depending on the solubility of the polyarylene ethers, the relative viscosities are measured either in 1% by weight N-methylpyrrolidone solution, in mixtures of phenol and dicorbenzene or in 96% sulfuric acid at 20 ° C. or 25 ° C. in each case.

Polyarylene ethers with repeating units I are known per se and can be prepared by known methods.

They arise, for example, from the condensation of aromatic bis-halogen compounds and the alkali double salts of aromatic bisphenols. They can also be produced, for example, by self-condensation of alkali salts of aromatic halophenols in the presence of a catalyst. Polyarylene ethers containing carbonyl functions are also accessible by electrophilic (Friedel-Crafts) polycondensation. In electrophilic polycondensation, either dicarboxylic acid chlorides or phosgene are reacted with aromatics, which contain two hydrogen atoms which are exchangeable by electrophilic substituents, to form the carbonyl bridges, or an aromatic carboxylic acid chloride which contains both an acid chloride group and a substitutable hydrogen atom, polycondensed with itself.

Preferred process conditions for the synthesis of polyarylene ether are described, for example, in EP-A-113 112 and 135 130. The reaction of the monomers in aprotic solvents, in particular N-methylpyrrolidone, in the presence of anhydrous alkali carbonate, in particular potassium carbonate, is particularly suitable. Implementing the monomers in the melt has also proven to be advantageous in many cases.

The polyarylene ethers of the general formula I can be used as end groups e.g. Hydroxy, chlorine, alkoxy, including preferably methoxy, phenoxy, amino or anhydride or mixtures of the end groups mentioned.

The thermoplastic polymers A can also be compounds based on substituted, in particular disubstituted, polyphenylene ether, the ether oxygen of one unit being bound to the benzene nucleus of the adjacent unit. Polyphenylene ethers substituted in the 2- and / or 6-position relative to the oxygen atom are preferably used. Examples of substituents are halogen atoms, such as chlorine or bromine, long-chain alkyl radicals with up to 20 carbon atoms, such as lauryl and stearyl, and short-chain alkyl radicals with 1 to 4 hydrocarbon atoms, which preferably have no α-tertiary hydrogen atom, for example methyl, ethyl, Propyl or butyl radicals to name. The alkyl radicals can in turn be substituted one or more times by halogen atoms, such as chlorine or bromine, or by a hydroxyl group. Further examples of possible substituents are alkoxy radicals, preferably having 1 to 4 carbon atoms or optionally by halogen atoms and / or C 1 -C ₄ -alkyl groups as defined above, mono- or polysubstituted phenyl radicals. Copolymers of various phenols, such as copolymers of 2, 6-dimethylphenol and 2, 3, 6-trimethylphenol, are also suitable. Mixtures of different polyphenylene ethers can of course also be used.

Examples of polyphenylene ethers which can be used according to the invention are poly (2,6-dilauryl-1, phenylene ether),

Poly (2,6-diphenyl-1,4-phenylene ether),

Poly (2,6-dimethoxy-1,4-phenylene ether),

Poly (2,6-diethoxy-1,4-phenylene ether),

Poly (2-methoxy-6-ethoxy-l, 4-phenylene ether), poly (2-ethyl-6-stearyloxy-l, 4-phenylene ether),

Poly (2,6-dichloro-1,4-phenylene ether),

Poly (2-methyl-6-phenyl-l, 4-phenylene ether), Poly (2,6-dibenzyl-1,4-phenylene ether), poly (2-ethoxy-1,4-phenylene ether), poly (2-chloro-1,4-phenylene ether), poly (2,5-dibromo-l , 4-phenylene ether).

Polyphenylene ethers which have alkyl radicals having 1 to 4 carbon atoms as substituents, such as poly (2,6-dimethyl-1,4-phenylene ether), poly (2,6-diethyl-1,4-phenylene ether), poly (2nd -methyl-6-ethyl-l, 4-phenylene ether), poly (2-methyl-6-propyl-l, 4-phenylene ether), poly (2, 6-dipropyl-l, 4-phenylene ether) and poly (2- ethyl 6-propyl-l, 4-phenylene ether).

For the purposes of the invention, polyphenylene ethers are also to be understood as meaning those which have been modified with monomers, such as fumaric acid, maleic acid or maleic anhydride.

Such polyphenylene ethers include described in WO 87/00540.

In particular, those polyphenylene ethers are used in the compositions which have an average molecular weight M _w (weight average) of about 8,000 to 70,000, preferably about 12,000 to 50,000 and in particular about 20,000 to 49,000.

This corresponds to an intrinsic viscosity of approximately 0.18 to 0.7, preferably approximately 0.25 to 0.55, and in particular approximately 0.30 to 0.50 dl / g, measured in chloroform at 25 ° C.

The molecular weights of the polyphenylene ethers are generally determined by means of gel permeation chromatography (Shodex separation columns 0.8 x 50 cm of the types A 803, A 804 and A 805 with THF as eluent at room temperature). The solution of the polyphenylene ether samples in THF is carried out under pressure at 110 ° C., 0.16 ml of a 0.25% by weight solution being injected.

The detection is generally carried out with a UV detector. The columns were calibrated using polyphenylene ether samples, the absolute molecular weight distribution of which was determined by a GPC / laser light scattering combination.

Furthermore, thermoplastic polymers A include polyether imides or mixtures of different polyether imides. In principle, both aliphatic and aromatic polyetherimides can be used as polyetherimides. Also suitable are polyetherimides which contain both aliphatic and aromatic groups in the main chain. For example, polyetherimides, the repeating units of the general formula II

0

included, are used, with Q 'being selected from, for example

and

wherein Z 'and R' can independently be the same or different. Z 'and R' can mean, for example, a Ci to C ₃ o-alkylene group. The alkylene group can be linear, branched or closed to form a ring. Among them are

Methylene, ethylene, n-propylene, i-propylene, cyclohexylene or n-decylene called. Z 'and R' can also represent a C ₇ - to C ₃ o-alkylarylene radical. Examples include diphenylene methane, diphenylene ethane or 2,2-diphenylene propane. Furthermore Z 'and R' can mean a C ₆ - to cis-arylene radical such as phenylene or biphenylene. The aforementioned groups can in turn be substituted by one or more substituents or interrupted by heteroatoms or groups. Particularly preferred substituents are halogen atoms, preferably chlorine or bromine or C 1 -C 10 -alkyl radicals, in particular methyl or ethyl. The preferred heteroatoms or groups include -S0 ₂ -, -O- or -S-. Some suitable radicals Z 'and R' are listed below by way of example:

wherein Q "- C _y H _2i CO - so ₂ - or -S- can mean q 0 or

Is 1, p is 0 or 1 and y is an integer from 1 to 5. R ″ can mean Ci to Cio-alkyl or Ci to Cio alkoxy, and r can be zero or 1. In addition to the units of the general formula II, the polyetherimides can also contain further imide units. For example, units of the formulas IIi or II ₂ or mixtures thereof are suitable:

Uli ⁾ (II ₂ ) Polyetherimides, the repeating units of the general formula III, are preferred

included, used, wherein Z "and R" have the same meaning as Z 'and R'.

Particularly preferred polyetherimides contain recurring units in which Z "

CH ₃

means and R "is selected from

Very particularly preferred polyetherimides contain recurring units of the formula (Uli)

The polyetherimides generally have average molecular weights (number average M _n ) of 5,000 to 50,000, preferably 8,000 to 40,000. They are either known or can be obtained by known methods. 5

Corresponding dianhydrides can be reacted with corresponding diamines to give the polyetherimides. As a rule, this reaction takes place in bulk or in an inert solvent at temperatures of 100 to 250 ° C. Suitable as a solvent

10 especially o-dichlorobenzene or m-cresol. Likewise, the polyetherimides can be produced in the melt at temperatures from 200 to 400 ° C., preferably 230 to 300 ° C. To prepare the polyetherimides, the dianhydrides are generally reacted with the diamines in an equimolar ratio. Certain molar excess

15 shots, e.g. 0.1 to 5 mol% of dianhydride or diamine, however, are possible.

According to the invention, polystyrenes can also be used as polymers A. Particularly suitable monomers are styrene, furthermore the styrenes alkylated in the nucleus or in the side chain. Examples include chlorostyrene, α-methylstyrene, styrene, p-methylstyrene, vinyl toluene and p-tert-butylstyrene. However, styrene is preferably used alone.

25 The homopolymers are generally according to the known

Processes prepared in bulk, solution or suspension (cf. Ullmanns Enzyklopadie der techn. Chemie, Volume 19, pages 265 to 272, Verlag Chemie, Weinheim 1980). The homopolymers can have a weight average molecular weight M _w of 100 to 300,000.

30 points that can be determined by conventional methods.

In addition, the thermoplastic polymers A can be copolymers based on styrene, including copolymers based on other vinyl aromatic monomers such as α-methylstyrene or substituted styrenes, e.g. Ci to CiQ alkyl styrenes such as methyl styrene or mixtures of different vinyl aromatic monomers are understood. For example, styrene copolymers are suitable

40 50 to 95 wt .-%, preferably 60 to 80 wt .-% styrene, α-methyl styrene or substituted styrenes, N-phenylmaleimide or mixtures thereof and

5 to 50 wt .-%, preferably 20 to 40 wt .-% acrylonitrile, methacrylonitrile, methyl methacrylate, maleic anhydride or mixtures thereof. The styrene copolymers are resinous, thermoplastic and rubber-free. Particularly preferred styrene copolymers are those made from styrene with acrylonitrile and optionally with methyl methacrylate, from α-methylstyrene with acrylonitrile and optionally with methyl methacrylate or from styrene and α-methylstyrene with acrylonitrile and optionally with methyl methacrylate and from styrene and maleic anhydride. Several of the styrene copolymers described can also be used simultaneously.

These styrene copolymers are known per se and can be prepared by radical polymerization, in particular by emulsion, suspension, solution and bulk polymerization. They generally have viscosity numbers in the range from about 40 to 160, this corresponds to average molecular weights M _w (weight average) of about 40,000 to 2,000,000.

Styrene copolymers of vinyl aromatic monomers, for example styrene or α-methylstyrene and conjugated dienes, can also be used in the process according to the invention. A particularly suitable vinyl aromatic monomer is styrene. The conjugated dienes include Butadiene or isoprene used, butadiene is preferably used. Copolymers which can be obtained by first polymerizing vinylaromatic monomers with conjugated dienes and then subjecting them to a hydrogenation reaction can also be used as styrene copolymers.

Such styrene copolymers are obtainable in particular by anionic polymerization of vinyl aromatic monomers and conjugated dienes. This mainly results in block copolymers of these comonomers. Methods for producing such styrene copolymers are generally known (US Pat. No. 3,595,942).

The styrene copolymers used can be of any structure, block copolymers with a three-block structure and branched, so-called star-shaped structures with a multi-block structure are particularly preferred. DE-OS 19 59 922 relates to the synthesis of star-shaped block copolymers from vinylaromatic monomers and diene monomers, the synthesis of star-shaped block copolymers with multiple initiation is the subject of DE 25 50 226 and US Pat. No. 3,639,517.

Suitable monomers and initiators can also be found in the publications mentioned. Block copolymers based on styrene as vinyl aromatic monomer and butadiene and / or isoprene as conjugated diene monomers are particularly preferred. The proportion of vinyl aromatic monomer in the styrene copolymers is generally from 25 to 95, preferably 40 to 90 wt .-%.

Graft copolymers which are preferably composed of can also be used as thermoplastic polymers A.

ai) about 40 to 80% by weight, preferably about 50 to 70% by weight, of a graft base made of a rubber-elastic polymer with a glass transition temperature of below 0 ° C.,

a ₂ ) about 20 to 60 wt .-%, preferably about 30 to 50 wt .-% of a graft

a ₂ χ) about 50 to 95 wt .-%, preferably about 60 to 80 wt .-% styrene or substituted styrenes of the above general formula III or methyl methacrylate or mixtures thereof

a ₂₂ ) about 5 to 50 wt .-%, preferably about 20 to 40 wt .-% acrylonitrile, methacrylonitrile, methyl methacrylate, maleic anhydride or mixtures thereof.

Polymers whose glass transition temperature is below 10 ° C., in particular below 0 ° C., preferably below -20 ° C., are suitable for the graft base ai). These are e.g. Natural rubber, synthetic rubber based on conjugated dienes, or their mixtures with other copolymers and elastomers based on Ci-Cs-alkyl esters of acrylic acid, which may contain other comonomers.

Preferred graft bases ai) are polybutadiene or copolymers of butadiene and styrene.

Graft bases ai) which are composed of are also preferred

an) 70 to 99.9% by weight, preferably 99% by weight of at least one alkyl acrylate with 1 to 8 carbon atoms in the alkyl radical, preferably n-butyl acrylate and / or 2-ethylhexyl acrylate, in particular n-butyl acrylate as the sole alkyl acrylate

aχ ₂ ) 0 to 30 wt .-%, in particular 20 to 30 wt .-% of a further copolymerizable, monoethylenically unsaturated monomer, such as butadiene, isoprene, styrene, acrylonitrile, methyl methacrylate and / or vinyl methyl ether a ₁₃ ) 0.1 to 5% by weight, preferably 1 to 4% by weight, of a copolymerizable, polyfunctional, preferably bi- or trifunctional, crosslinking monomer.

Suitable such bi- or polyfunctional crosslinking monomers aχ ₃ ) are monomers which preferably contain two, optionally also three or more, ethylenic double bonds which are capable of copolymerization and which are not conjugated in the 1,3 positions. Suitable crosslinking monomers are, for example, divinylbenzene, diallyl maleate, diallyl fumarate, diallyl phthalate,

Triallyl cyanurate or triallyl isocyanurate. The acrylic acid ester of tricyclodecenyl alcohol has proven to be a particularly favorable crosslinking monomer (cf. DE-A-12 60 135).

This type of graft base is also known per se and is described in the literature.

Of the graft a ₂ ) preferred are those in which a21) means styrene or α-methylstyrene. The preferred monomer mixtures used are especially styrene and acrylonitrile, α-methylstyrene and acrylonitrile, styrene, acrylonitrile and methyl methacrylate, styrene, N-phenylmaleimide and maleic anhydride. The grafting pads can be obtained by copolymerizing components a ₂ ι) and a ₂₂ ) •

In the event that the graft copolymer contains a graft base ai) which is composed of polybutadiene polymers, one speaks of ABS rubber.

As is known per se, the graft copolymerization can take place in solution, suspension or preferably in emulsion. The soft phase of the graft copolymer preferably has an average particle diameter (dso value of the integral mass distribution) of 0.08 μm during the production of the ABS rubber and the grafting in emulsion. The dso value is set in the range from 0.2 to 0.5 μm by enlarging the particles, for example by agglomeration or when the emulsion is obtained by means of the seed latex process. In the case of such graft copolymerizations, the polymerizing monomers are at least partially chemically linked to the already polymerized rubber, the link probably occurring at the double bonds contained in the rubber. At least some of the monomers are thus grafted onto the rubber, that is to say bound to the rubber thread molecules by covalent bonds. The grafting can also be carried out in several stages by first grafting on part of the monomers forming the graft shell and then the rest.

If the graft base ai) of the graft copolymers composed of the components an), optionally aχ ₂ ) and aι ₃ ), one speaks of ASA rubbers. Their production is known per se or can be carried out according to methods known per se.

The graft layers of the graft copolymers can be built up in one or two stages.

In the case of the one-stage structure of the graft layers, a mixture of the monomers a ₂ ι) and a ₂ 2) in the desired weight ratio is in the range from 95: 5 to 50:50, preferably 90:10 to 65:35 in Presence of the elastomer & χ, polymerized in a manner known per se, preferably in emulsion.

In the case of a two-stage structure of the graft layers a ₂ ), the first stage generally makes up 20 to 70% by weight, preferably 25 to 50% by weight, based on a ₂ ). Only monoethylenically unsaturated aromatic hydrocarbons (a ₂ i) are preferably used for their preparation.

The second stage of the graft layers generally makes up 30 to 80% by weight, in particular 50 to 75% by weight, based in each case on a ₂ ). For their preparation, mixtures of the monoethylenically unsaturated aromatic hydrocarbons a ₂ ι) and monoethylenically unsaturated monomers a ₂₂ ) in the weight ratio a ₂ ι) / a ₂₂ ) of generally 90:10 to 60:40, in particular 80, are used : 20 to 70:30 applied.

The conditions of the graft copolymerization are preferably chosen so that particle sizes from 50 to 700 nm (d ₅ o-value of the inte- Gralen mass distribution) result. Measures for this are known.

A coarse-particle rubber dispersion can be produced directly using the seed latex process.

In order to achieve products that are as tough as possible, it is often advantageous to use a mixture of at least two graft copolymers with different particle sizes. To achieve this, the particles of the rubber are enlarged in a known manner, for example by agglomeration, so that the latex is built up bimodally (for example 50 to 180 nm and 200 to 700 ran).

Furthermore, copolymers of α-olefins may be mentioned as thermoplastic polymers A. The α-olefins are usually monomers with 2 to 8 carbon atoms, preferably ethylene and propylene. Suitable comonomers are alkyl acrylates or alkyl methacrylates which are derived from alcohols having 1 to 8 carbon atoms, preferably from ethanol, butanol or ethylhexanol, and reactive comonomers such as acrylic acid, methacrylic acid, maleic acid, maleic anhydride or glycidyl (meth) acrylate and furthermore, vinyl esters, in particular vinyl acetate, have been found to be suitable. Mixtures of different comonomers can also be used. Ethylene copolymers with ethyl or butyl acrylate and acrylic acid and / or maleic anhydride have proven to be particularly suitable as comonomers.

The copolymers can be produced in a high pressure process at a pressure of 400 to 4500 bar or by grafting the comonomers onto the poly-α-olefin. The proportion of the α-olefin in the copolymer is generally in the range from 99.95 to 55% by weight.

Lactam b can be, for example, ε-caprolactam, enanthacta, capryllactam and lauryllactam and mixtures thereof, preferably ε-caprolactam.

Other polyamide-forming monomers that can be used are, for example, dicarboxylic acids, such as alkanedicarboxylic acids having 6 to 12 carbon atoms, in particular 6 to 10 carbon atoms, such as adipic acid, pimelic acid, suberic acid, azelaic acid or sebacic acid, and terephthalic acid and isophthalic acid, diamines such as C ₄ -C ₂ -alkyl- diamines, in particular with 4 to 8 carbon atoms such as hexamethylene diamine, tetramethylene diamine or octamethylene diamine, also m-xylylenediamine, bis- (4-aminophenyl) methane, bis- (4-aminophenyl) propane-2,2 or bis- ( 4 -aminocyclohexyl) methane, and mixtures of dicarboxylic acids and diamines, each in any combination, but advantageously in relation to one another in an equivalent ratio such as hexamethylene diammonium adipate, hexamethylene diammonium terephthalate or tetramethylene diammonium adipate, preferably hexamethylene diammonium adipate and hexamethylene adipate. Polycaprolactam and polyamides, which are composed of caprolactam, hexamethylenediamine and adipic acid, isophthalic acid and / or terephthalic acid, have acquired particular industrial importance. In a preferred embodiment, ε-caprolactam and hexamethylene diammonium adipate ("AH salt") are used.

In general, from 30 to 100, preferably from 35 to 100,% by weight, based on the total amount of monomers b, of lactates and from 0 to 70, preferably from 0 to 65% by weight, based on the total amount of monomers b, the other polyamide-forming monomers. AH salt is usually used as an aqueous solution, the concentration of which is generally from 30 to 75% by weight, preferably from 35 to 70% by weight, based on the aqueous solution. As a rule, the weight ratio of lactam to AH salt is selected in the range from 4: 1 to 20: 1, preferably in the range from 5: 1 to 15: 1.

According to the invention, the polyamide-forming monomers b in which the polymers A are dissolved are polymerized in the presence of 0.001 to 5% by weight of water, based on the monomers b. The polymerization is preferably carried out in the presence of more than 0.005% by weight of water, for example from 0.01 to 5% by weight of water. Amounts of water in the range from 0.1 to 4.5, in particular 0.5 to 4,% by weight of water, based on the monomers b, are particularly preferred. Under these conditions, the rate of polymerization is sufficiently high, and the thermoplastic polymers A surprisingly remain in solution or finely dispersed.

The water can be added to the solution from the thermoplastic polymer A in the polyamide-forming monomers b. If these solutions already contain water, for example because the AH salt is used as an aqueous solution, either no further water is added or only so much water is added that the total amount of water, based on the monomers b, is in the range according to the invention.

In general, the thermoplastic polymers A are added to the polamide-forming monomers b. However, the polymers A can also be introduced and the polyamide-forming monomers b added. The proportion of thermoplastic polymers A in the solution is generally from 1 to 75% by weight. Accordingly, the proportion of the polyamide-forming monomers is from 25 to 99% by weight. The solution preferably contains from 2 to 75, in particular from 3 to 70,% by weight of the thermoplastic polymers A and from 25 to 98, in particular from 30 to 97% by weight of the polyamide-forming monomers b.

Depending on the melting point of the polyamide-forming monomers, the polymers A are dissolved in the monomers b at temperatures in the range from 50 to 300, preferably in the range from 80 to 290. In order to If good mixing of the solution components is obtained, the mixture of A and b is advantageously stirred. For example, stirred tanks are suitable for this. The water is then generally added all at once, in portions or continuously. The temperature of the solution is increased either simultaneously or subsequently, as a rule, to 180 to 330, preferably 220 to 310 ° C. The solution can either remain in the unit in which it was produced or can be transferred to another reaction vessel before or after the temperature increase or before or after the addition of water.

Various processes can be used for the production of the compositions according to the invention. For example, according to EP-A 129 195 and 129 196, the polymerization in tubes can be carried out under pressure up to certain conversions to form a prepolymer which is subsequently condensed. A two-stage process, which is also suitable for the production of the compositions according to the invention, is known from US 2,241,322. Suitable post-condensation conditions are described, for example, in EP-A 38 094.

The preferred process is generally carried out in such a way that the water-containing solution, which is preheated to a temperature in the range from 75 to 90 ° C., is passed into a reaction vessel, this reaction mixture being heated to a temperature in the range from 220 to 310, preferably heated from 240 to 290 ° C.

The reaction vessel advantageously has internals such as ordered mixing elements (e.g. so-called Sulzer packs) or unordered mixing elements such as packing elements (e.g. Raschig rings, balls or

Pall rings), so that preferably a minimum residence time of the monomers in the melt is ensured (in order to achieve a high conversion), and zones in which there is no or only minimal transport of the melt ("dead zones") and backmixing are avoided as far as possible.

The reaction pressure is generally chosen so that the reaction mixture is liquid in one phase. This is advantageous since the formation of gas cushions generally causes the flow to pulsate, which would result in back-mixing and uneven polymerisation. The pressure here is generally in the range from 5 to 30, preferably from 8 to 18, bar (absolute).

The residence time, which essentially depends on the temperature, pressure and water content of the reaction mixture, is generally chosen in the range from 2 to 4 h, preferably from 2 to 2.5 h. In case of Action times of less than 2 hours and a water content of less than 1% by weight generally only give sales of less than 86%. Reaction times of more than 4 hours generally lead to poor space-time yields, which is also associated with larger and more technically complex reactors.

When caprolactam is used, a composition is usually obtained after the first reaction zone which contains polycaprolactam with a molecular weight in the range from 3000 to 9000, preferably from 5000 to 6700 g / mol. The end group sum concentration is generally in the range from 220 to 670, preferably from 300 to 400 mmol / kg, the melt viscosity in the range from 100 to 10,000, preferably from 200 to 4000 mPas (at 270 ° C.).

The turnover (calculated from the extract content, whereby

Turnover = 100 - extract content

applies) according to the invention is at least 85%, preferably greater than or equal to 87%, particularly preferably greater than or equal to 89%.

In general, the pressurized reaction mixture is decompressed adiabatically, ie a decompression is carried out in which the heat required for evaporation is not supplied from the outside in a second reaction zone, the pressure in the second reaction zone generally being in the range from 0.1 mbar to 1.1 bar is selected, preferably in the range from 500 to 1050 mbar. In general, in this case the reaction mixture C is cooled from the first reaction zone to temperatures in the range of 215 to 300 ° from, preferably 235-265 ⁰ C.

In addition, components which are volatile with the steam, such as the lactam used and further monomer units and also steam-volatile oligomers thereof, are expediently removed in the second reaction zone. In a further preferred embodiment, the volatile constituents are continuously returned quantitatively to the process, i.e. preferably in the first reaction zone.

The residence time in the second reaction zone is generally chosen in the range from 2 to 60 minutes, preferably from 3 to 30 minutes. When caprolactam is used, the preferred process usually gives a composition after the second reaction zone which contains polycaprolactam with a molecular weight in the range from 3000 to 14000, preferably from 6000 to 12000 g / mol. The end group total concentration is generally in the range from 140 to 670, preferably from 170 to 330 mmol / kg, the melt viscosity in the range from 100 to 10,000, preferably from 200 to 4000 Pas (at 270 ° C.).

The compositions produced by the process according to the invention contain, in addition to the polyamide B obtained from b or the mixtures of different polyamides B, at least one thermoplastic polymer A. In addition, the compositions thus prepared contain compounds which are derived from reactions of the polymers A with the monomers b or the polymers Derive B or their mixtures. The polymers A are not or only slightly degraded, so that the chain length of the polymers A is essentially retained.

As a rule, one is obtained after the second reaction zone

Composition which can be made into pieces according to customary methods, for example by discharging the composition in the form of melting profiles, then passing it through a water bath and in the process cooling and then granulating.

The composition obtained according to the invention can be extracted by methods known per se. Subsequently or at the same time, the polyamide B contained in the composition can be converted to a higher or high molecular weight polyamide B.

For example, the composition can be extracted with water in countercurrent (see DD-A 206999). The desired viscosity number of the end product, which is generally in the range from 80 to 350 ml / g, can be set in a manner known per se by drying or, in the solid phase, by polycondensation in the solid phase.

Another possibility for further processing is gas phase extraction (see EP-A 284968) with simultaneous build-up of molecular weight, in which extraction and annealing can be carried out simultaneously using superheated steam. The desired viscosity number of the end product is generally also in the range from 80 to 350 ml / g. The compositions may contain additives. The additives are generally added before the granulation and / or before, during or after, preferably after the polymerization of the monomers b.

The compositions may contain from 0 to 40, preferably from 1 to 30,% by weight, based on the overall composition, of one or more impact-modifying rubbers as additives.

For example, Usual impact modifiers are used, which are suitable for polyamides and / or the polymers A.

Rubbers which increase the toughness of polyamides generally have two essential features: they contain an elastomeric component which has a glass transition temperature of less than -10 ° C., preferably less than -30 ° C., and they contain at least one functional one Group that can interact with the polyamide. Suitable functional groups are, for example, carboxylic acid, carboxylic anhydride, carboxylic ester, carboxamide, carboximide, amino, hydroxyl, epoxy, urethane and oxazoline groups.

As rubbers which increase the toughness of the blends, e.g. called the following:

EP or EPDM rubbers with the above functional groups were grafted. Suitable grafting reagents are, for example, maleic anhydride, itaconic acid, acrylic acid, glycidyl acrylate and glycidyl methacrylate.

These monomers can be grafted onto the polymer in the melt or in solution, if appropriate in the presence of a radical initiator such as cumene hydroperoxide.

The copolymers of α-olefins described under the polymers A, including in particular the ethylene copolymers, can also be used as rubbers instead of polymers A and added to the compositions according to the invention as such.

Core-shell graft rubbers are another group of suitable elastomers. These are graft rubbers made in emulsion and consist of at least one hard and one soft component. A hard component is usually understood to mean a polymer with a glass transition temperature of at least 25 ° C., and a soft component partly a polymer with a glass transition temperature of at most 0 ° C. These products have a structure consisting of a core and at least one shell, the structure resulting from the order in which the monomers are added. The soft components are generally derived from butadiene, isoprene, alkyl acrylates, alkyl methacrylates or siloxanes and optionally other comonomers. Suitable siloxane cores can be prepared, for example, from cyclic oligomeric octamethyltetrasiloxane or tetravinyltetramethyltetrasiloxane. These can be reacted, for example, with γ-mercaptopropylmethyldimethoxysilane in a ring-opening cationic polymerization, preferably in the presence of sulfonic acids, to give the soft siloxane cores. The siloxanes can also be crosslinked, for example by carrying out the polymerization reaction in the presence of silanes with hydrolyzable groups such as halogen or alkoxy groups such as tetraethoxysilane, methyltrimethoxysilane or phenyltrimethoxysilane. Examples of suitable comonomers here are styrene, acrylonitrile and crosslinking or graft-active monomers with more than one polymerizable double bond, such as diallyl phthalate, divinylbenzene, butanediol diacrylate or triallyl (iso) cyanurate. The hard constituents are generally derived from styrene, α-methylstyrene and their copolymers, the preferred comonomers here being acrylonitrile, methacrylonitrile and methyl methacrylate.

Preferred core-shell graft rubbers contain a soft core and a hard shell or a hard core, a first soft shell and at least one further hard shell. Functional groups such as carbonyl, carboxylic acid, acid anhydride, acid amide, acid imide, carboxylic ester, amino, hydroxyl, epoxy, oxazoline, urethane, urea, lactam or halobenzyl groups are incorporated here preferably by adding suitably functionalized monomers in the polymerization of the last shell. Suitable functionalized monomers are, for example, maleic acid, maleic anhydride, mono- or diester or maleic acid, tertiary butyl (meth) acrylate, acrylic acid, glycidyl (meth) acrylate and vinyloxazoline. The proportion of monomers with functional groups is generally 0.1 to 25% by weight, preferably 0.25 to 15% by weight, based on the total weight of the core-shell graft rubber. The weight ratio of soft to hard components is generally 1: 9 to 9: 1, preferably 3: 7 to 8: 2.

Rubbers of this type which increase the toughness of polyamides are known per se and are described, for example, in EP-A 208 187. Another group of suitable impact modifiers are thermoplastic polyester elastomers. Polyester elastomers are understood to mean segmented copolyether esters which contain long-chain segments which are generally derived from poly (alkylene) ether glycols and short-chain segments which are derived from low molecular weight diols and dicarboxylic acids. Products of this type are known per se and are described in the literature, for example in US Pat. No. 3,651,014. Corresponding products are also commercially available under the names Hytrel® (Du Pont), Arnitel® (Akzo) and Pelprene® (Toyobo Co. Ltd.).

Mixtures of different rubbers can of course also be used.

In addition, the compositions can also contain fillers or reinforcing agents, generally in amounts of 0 to 40% by weight, based on the total weight of the compositions.

Examples of fibrous fillers or reinforcing materials are carbon fibers, potassium titanate whiskers, aramid fibers and particularly preferably glass fibers. If glass fibers are used, they can be equipped with a size and an adhesion promoter for better compatibility with the matrix material. In general, the carbon and glass fibers used have a diameter in the range from 6 to 20 μm.

The glass fibers can be incorporated both in the form of short glass fibers and in the form of endless strands (rovings). In the finished injection molded part, the average length of the glass fibers is preferably in the range from 0.08 to 0.5 mm.

Carbon or glass fibers can also be used in the form of fabrics, mats or glass silk rovings.

Suitable particulate fillers are amorphous silica, carbonates such as magnesium carbonate (chalk), powdered quartz, mica, a wide variety of silicates such as clays, muscovite, biotite, suzoite, tin maletite, talc, chlorite, phlogophite, feldspar, calcium silicates such as wollastonite or kaolin, especially calcined ter kaolin.

According to a particularly preferred embodiment, particulate fillers are used, of which at least 95% by weight, preferably at least 98% by weight, of the particles have a diameter (greatest extent), determined on the finished product, of less than 45 μm, preferably less than 40 μm have and their saw named aspect ratio in the range from 1 to 25, preferably in the range from 2 to 20, determined on the finished product.

The particle diameters can e.g. are determined by taking electron micrographs of thin sections of the polymer mixture and using at least 25, preferably at least 50 filler particles for the evaluation. The particle diameters can also be determined via sedimentation analysis, according to Transactions of ASAE, page 491 (1983). The weight fraction of the fillers, which is less than 40 μm, can also be measured by sieve analysis. The aspect ratio is the ratio of particle diameter to thickness (largest dimension to smallest dimension).

Talc, kaolin, such as calcined kaolin or wollastonite or mixtures of two or all of these fillers are particularly preferred as particulate fillers. Among them, talc with a proportion of at least 95% by weight of particles with a diameter of less than 40 μm and an aspect ratio of 1.5 to 25, each determined on the finished product, is particularly preferred. Kaolin preferably has a proportion of at least 95% by weight of particles with a diameter of less than 20 μm and an aspect ratio of 1.2 to 20, each determined in the finished product.

Further additives include processing aids, stabilizers and oxidation retardants, agents against heat decomposition and decomposition by ultraviolet light, lubricants and mold release agents, flame retardants, dyes and pigments and plasticizers. Their proportion is generally up to 40, preferably up to 15% by weight, based on the total weight of the composition.

Pigments and dyes are generally present in amounts of 0 to 4, preferably 0.5 to 3.5 and in particular 0.5 to 3% by weight.

The pigments for coloring thermoplastics are generally known, see, for example, R. Gächter and H. Müller, Taschenbuch der Kunststoffadditive, Carl Hanser Verlag, 1983, pp. 494 to 510. The first preferred group of pigments are white pigments such as zinc oxide and zinc sulfide , Lead white (2 PbC0 ₃ .Pb (OH) ₂ ), lithopone, antimony white and titanium dioxide. Of the two most common crystal modifications (rutile and anatase type) of titanium dioxide, the rutile form is used in particular for the white coloring of the molding compositions according to the invention. Black color pigments which can be used according to the invention are iron oxide black (Fe ₃ 0 ₄ ), spinel black (Cu (Cr, Fe) ₂ O ₄ ), manganese black (mixture of manganese dioxide, silicon dioxide and iron oxide), cobalt black and antimony black and are particularly preferred Soot, which is mostly used in the form of furnace or gas black (see G. Benzing, Pigments for Paints, Expert Verlag (1988), p. 78ff).

Of course, inorganic colored pigments such as chrome oxide green or organic can be used to adjust certain shades

Colored pigments such as azo pigments and phthalocyanines are used according to the invention. Pigments of this type are generally commercially available.

It may also be advantageous to use the pigments or dyes mentioned in a mixture, e.g. Carbon black with copper phthalocyanines, since it is generally easier to disperse colors in thermoplastics.

Oxidation retarders and heat stabilizers which can be added to the thermoplastic compositions according to the invention are e.g. Group I metals of the Periodic Table, e.g. Sodium, potassium, lithium halides, optionally in combination with copper (I) halides, e.g. Chlorides, bromides or iodides. The halides, especially of copper, can also contain electron-rich π ligands. An example of such copper complexes are Cu halide complexes with e.g. Called triphenylphosphine. Zinc fluoride and zinc chloride can also be used. Sterically hindered phenols, hydroquinones, are also substituted. Representatives of this group, secondary aromatic amines, optionally in combination with phosphorus-containing acids or their salts, and mixtures of these compounds, preferably in concentrations of up to 1% by weight, based on the weight of the mixture.

Examples of UV stabilizers are various substituted resorcinols, salicylates, benzotriazoles and benzophenones, which are generally used in amounts of up to 2% by weight.

Lubricants and mold release agents, which are generally added in amounts of up to 1% by weight of the thermoplastic composition, are stearic acid, stearyl alcohol, alkyl stearates and amides, and esters of pentaerythritol with long-chain fatty acids. Salts of calcium, zinc or aluminum of stearic acid and dialkyl ketones, for example distearyl ketone, can also be used. The advantages of the process according to the invention over known processes are, inter alia, that the chain length of the thermoplastic polymers A is not or only slightly shortened and the polymers A are very finely dispersed in the compositions, as a result of which the compositions have very good mechanical properties. In particular, they are characterized by good rigidity, good flow properties and excellent toughness.

Another advantage is the light intrinsic color of the compositions which can be obtained by the process according to the invention.

Because the compositions obtainable by the process according to the invention contain the polymers A and the polyamides B in a particularly finely divided form, they are suitable as compatibilizers in polymer mixtures, the components of which are each incompatible with one another, but either with the polymer A or the polyamide B of the composition are tolerated.

Examples of components α of such polymer mixtures which are compatible with the polymers A of the compositions are those described under A. Component α can comprise a polymer or be a mixture of two or more polymers. Component α can be chosen so that it corresponds to the polymer or polymers A of the composition. However, component α need not be equal to A. Thus, α can be a polyphenylene ether and A can be a styrene polymer or α can be a polyarylene ether of a certain structure, while A is a differently constructed polyarylene ether. The polymers A and α can e.g. also differ by different molecular weights or molecular weight distributions. In general, component α is present in the polymer mixtures in proportions of from 1 to 97% by weight, preferably from 5 to 90% by weight, based on the total weight of the polymer mixtures.

As already mentioned above, all polymers which are compatible with the polyamides B of the composition can be considered as component β. A polymer ß or a mixture of two or more different polymers ß can be used. Thermoplastic polyamides are particularly preferably used. Such polyamides are known per se and comprise partially crystalline and amorphous resins with a molecular weight (weight average) of at least 5000 g / mol, which are usually referred to as nylon. Such polyamides are described, for example, in US Pat. Nos. 2,071,250, 2,071,251, 2,130,523, 2,130,948, 2,241,322, 2,312,966, 2,512,606 and 3,393,210. The polyamides ß can be prepared, for example, by condensation of equimolar amounts of a saturated or an aromatic dicarboxylic acid having 4 to 12 carbon atoms, with a saturated or aromatic dia in which has up to 14 carbon atoms or by 5 condensation of ω-aminocarboxylic acids or polyaddition of corresponding lactams .

Examples of such polyamides are polyhexamethylene adipic acid amide (nylon 66), polyhexamethylene azelaic acid amide (nylon 69),

10 polyhexamethylene sebacic acid amide (nylon 610), polyhexamethylene dodecanedioic acid amide (nylon 612), the polyamides obtained by ring opening of lactams such as polycaprolactam, polylauric acid lactam, also poly-11-aminoundecanoic acid and a polyamide made from di (p-amino-cyclohexyl) methane acid and dodecane .

15

It is also possible to use polyamides as component β which have been prepared by copolycondensation of two or more of the above-mentioned polymers or their components, e.g. Copolymers of adipic acid, isophthalic acid or terephthalic acid and

20 hexamethylene diamine or copolymers of caprolactam, terephthalic acid and hexamethylene diamine. Such partially aromatic copolyamides generally contain from 40 to 90% by weight of units which are derived from terephthalic acid and hexamethylenediamine. A small proportion of terephthalic acid, preferably not more than

25 10% by weight of the total aromatic dicarboxylic acids used can be replaced by isophthalic acid or other aromatic dicarboxylic acids, preferably those in which the carboxyl groups are in the para position.

30 Cyclic diamines such as those of the general formula IV also come as monomers for the production of the polyamides β

40 in

R ^{1 is} hydrogen or a -C ₄ alkyl group,

R ^{2 is} a -C ₄ alkyl group or hydrogen and

R ^{3 represents} a C _] _ -C ₄ alkyl group or hydrogen.

45 Particularly preferred diamines IV are bis (4-aminocyclohexyl) methane, bis (4-amino-3-methylcyclohexylmethane, bis (4-aminocyclohexyl) -2, 2-propane or bis (4-amino-3-methylcyclohexyl) - 2, 2 - propane.

1,3- or 1,4-cyclohexanediamine or isophoronediamine may be mentioned as further diamines IV.

In addition to the units derived from terephthalic acid and hexamethylene diamine, the partially aromatic copolyamides contain

Units derived from ε-caprolactam and / or units derived from adipic acid and hexamethylenediamine.

The proportion of units derived from ε-caprolactam is up to 50% by weight, preferably 20 to 50% by weight, in particular 25 to 40% by weight, while the proportion of units derived from adipic acid and hexamethylenediamine, is up to 60% by weight, preferably 30 to 60% by weight and in particular 35 to 55% by weight.

The copolyamides can also contain units of ε-caprolactam as well as units of adipic acid and hexamethylenediamine; in this case care must be taken to ensure that the proportion of units which are free from aromatic groups is at least 10% by weight, preferably at least 20% by weight. The ratio of the units derived from ε-caprolactam and from adipic acid and hexamethylenediamine is not subject to any particular restriction.

Polyamides β with 50 to 80, in particular 60 to 75,% by weight units derived from terephthalic acid and hexamethylenediamine and 20 to 50, preferably 25 to 40,% by weight units which have been found to be particularly advantageous for many applications Derive ε-caprolactam, proven.

The production of the partially aromatic copolyamides β can e.g. by the method described in EP-A-129 195 and EP 129 196.

Preferred partially aromatic polyamides β are those which have a content of triamine units, in particular units of dihexamethylene triamine, of less than 0.5% by weight. Such partially aromatic polyamides β with triamine contents of 0.3% by weight or less are particularly preferred. Linear polyamides with a melting point above 200 ° C. are preferably used as component β.

Preferred polyamides β are polyhexamethylene adipic acid amide, polyhexamethylene sebacic acid amide and polycaprolactam as well as polyamide 6 / 6T and polyamide 66 / 6T as well as polyamides which contain cyclic diamines as comonomers. The polyamides generally have a relative viscosity of 2.0 to 5, determined on a 1 wt. -% solution in 96% sulfuric acid at 23 ° C, which corresponds to a molecular weight (number average) of about 15,000 to 45,000. Polyamides with a relative viscosity of 2.4 to 3.5, in particular 2.5 to 3.4, are preferably used.

In addition, polyamides may also be mentioned as component β, which e.g. can be obtained by condensing 1,4-diaminobutane with adipic acid at elevated temperature (polyamide 4.6). Manufacturing processes for polyamides of this structure are e.g. in EP-A 38 094, EP-A 38 582 and EP-A 39 524.

The proportion of component β in the polymer mixtures can be from 1 to 97, preferably from 5 to 90,% by weight, based on the total weight of the polymer mixture.

The compositions used according to the invention as compatibilizers γ in the polymer mixtures can be used either as such or already provided with additives. The compositions as such are preferably used as component γ. As a rule, the polymer mixtures contain from 2 to 80, preferably from 5 to 70,% by weight, based on the total weight of the polymer mixture, of component γ.

In addition, the polymer mixtures can contain, as a further component δ, one or a mixture of two or more impact-modifying rubbers. Suitable as component δ are those already described above as additives for the compositions. If the component γ already contains impact-modifying rubbers, these can either be identical or different from those additionally present as component δ in the polymer mixtures. The polymer mixtures generally contain from 0 to 30, preferably from 0 to 25,% by weight, based on the total weight of the polymer mixtures, of component δ.

According to one of the preferred embodiments, the polymer mixtures contain fillers or reinforcing agents ε. Examples of suitable fillers or reinforcing agents are those already described above for the compositions. The polymer mixtures can contain from 0 to 40, preferably from 0.5 to 20,% by weight of component ε.

Furthermore, the polymer mixtures can contain additives such as processing aids, stabilizers, oxidation retardants, agents against decomposition by heat or light, lubricants or mold release agents, flame retardants, dyes, pigments or plasticizers. Of course, mixtures can also contain two or more additives in the polymer mixtures.

10 Suitable additives that can be used in the polymer blends include those mentioned as additives for the compositions. Component χ can differ from the additives used in the component. In general, the proportion of component χ in the polymer

15 mixtures from 0 to 30, preferably from 0 to 20% by weight, based on the total weight of the polymer mixtures.

The polymer blends can e.g. are produced by mixing the components in conventional mixing devices such as mixers, 20 kneaders, extruders, for example screw extruders, preferably twin-screw extruders, mills such as Banbury or Brabender mills, and then extruding them.

After extrusion, the extrudate is usually cooled and comminuted.

The order of mixing the components can be varied, so two or possibly three components can be premixed, but all components can also be mixed together.

In order to obtain a molding material that is as homogeneous as possible, intensive mixing is advantageous. This generally requires average mixing times of 0.2 to 30 minutes at temperatures of 280 to 35 380 ° C.

The polymer mixtures are particularly characterized by their good toughness. Both the compositions and the polymer mixtures are suitable for the production of moldings, films or fibers. One area in which these materials can be used particularly well is the automotive industry.

Examples

5 application studies: The proportion of units containing acid groups in the polyarylene ether sulfone A2 was determined by means of ^ H NMR measurements according to Parsons et al., Polymer 34, 2836 (1994).

The viscosity number of the polyarylene ether sulfones were increased

1 wt .-% solutions in N-methylpyrrolidone determined at 25 ° C.

The molecular weight of the polyphenylene ether was determined by means of gel permeation chromatography (under the conditions specified in the description).

The dried granulate from the compositions was processed into standard small bars, round disks and tensile bars. The dried granules of the polymer mixtures were processed to ISO rods and round discs. Processing was carried out at a melt temperature of 280 ° C and a mold temperature of 80 ° C.

The melt volume index (MVI value) was determined at a temperature of 275 ° C. and a load of 5 kg.

The modulus of elasticity (modulus of elasticity [N / mm ² ]) was determined in accordance with DIN 53 457 from the inclination of the tangent at the origin of the tension curve at a test speed of 1 mm per minute on tensile bars (average of 10 tests).

The notched impact strengths (a ^ [kJ / m ² ]) were determined on standard small bars according to DIN 53 453 by exposing the exposed small standard bars to a sudden impact load, the energy for breaking the bars being determined (10 individual tests).

The impact strengths (a _n [kJ / m ² ]) were measured on non-notched ISO rods in accordance with ISO 179 Part I.

The puncture work (Wges N / m) was determined on round disks according to DIN 53 443 by puncturing a firmly clamped round disk with a piercing body at a constant speed (4.5 m / s). The penetration work was determined from the force-deformation curve (5 individual measurements).

The color of the compositions was assessed optically. The color scale ranged from very light (1) to beige (2) and brownish (3) to brown (4) and dark brown (5).

Amorphous polymers AI to A4 AI: polyarylene ether sulfone having repeat units of the formula _I2, characterized by a viscosity number of 48 ml / g, for example Ultrason ^® S 1010 from BASF.

A2: Polyarylene ether sulfone containing acid groups

Under a nitrogen atmosphere, 5.742 kg of dichlorodiphenyl sulfone, 4.374 kg of bisphenol A and 112 g of 4,4'-di-hydroxyvaleric acid were dissolved in 29 kg of N-methylpyrrolidone, and 2.820 kg of anhydrous potassium carbonate were added.

The reaction mixture was first heated to 180 ° C. for 1 h at a pressure of 300 mbar while continuously distilling off the water of reaction and N-methylpyrrolidone and then reacted further at 190 ° C. for 6 h.

After adding 40 kg of N-methylpyrrolidone, the inorganic constituents were filtered off. Basic groups were neutralized by adding 50 ml of glacial acetic acid, and the polymer was then isolated by precipitation in water. After extraction with water, the product was dried at 140 ° C. in vacuo. A white powder was obtained.

The proportion of units with acid groups was determined by means of H-NMR to be 1.4% by weight, the viscosity number of the product was 38.1 ml / g.

A3: Polyphenylene ether, characterized by an average molecular weight (weight average) of 40,000 g / mol, determined by gel permeation chromatography and chloroform as solvent.

A4: poly (styrene-co-acrylonitrile), characterized by a

Acrylonitrile fraction of 25 wt -.% And a viscosity number of 80 ml / g (measured at 0.5 wt -.% Solutions in dimethylformamide at 25 ° C, eg Luran ^® 358 N from BASF).

Additives:

CI: Glass fiber with a fiber thickness of 10 μm and a polyurethane size.

C2: Talc with an average particle size of 1.5 μm. D: Ethylene propylene rubber, modified with 0.7% by weight maleic / maleic anhydride, characterized by an MFI value of 3 g per 10 min (measured under a load of 2.16 kg and 230 ° C.).

Preparation of composition 1 and comparative tests V6 and V7

8 kg of the polymer AI were dissolved in 24 kg of caprolactam. After 1000 g of water had been added, the mixture was heated to 235 ° C. in a stirred kettle, the internal pressure being 7.5 bar. After a precondensation of 2 hours, the vessel was depressurized over a period of 1.5 hours and then post-condensed at 235 ° C. for 2.5 hours.

The melt was then discharged from the kettle and granulated. The granules obtained were extracted with hot water.

The results obtained in the characterization of this product are listed in Table 1.

Compositions 2 to 5, V6 and V7 were prepared analogously. The amounts used and the results of the application tests are shown in Table 1.

Comparative tests

For comparison purposes, the polyarylene ether Al was characterized with a polyamide 6, characterized by a viscosity number of 146 ml / g (measured on 0.5% by weight solution in 96% by weight sulfuric acid) (for example Ultramid B from BASF) ) in an extruder (ZSK 30 from Werner and Pfleiderer) mixed at 280 ° C and then granulated. The granules obtained were dried at 80 ° C. in vacuo over a period of six hours. The results are shown in Table 1 (V8).

Molding compositions V9 to Vll were also produced accordingly, but molding composition Vll was processed at a mass temperature of 250 ° C. Table 1 :

R: stirred kettle

E: extruder

a) no polymerization

The granulated compositions 1, 2 and 5 were mixed with either the glass fibers C or the rubbers D in an extruder at a melt temperature of 280 ° C. The mixtures were then granulated and processed into test specimens.

For comparison purposes, the granulated molding compositions of the polymers AI or A4 and the polyamide 6 were mixed with the glass fibers C in an extruder (see comparative examples V15 and V16). The compositions and mechanical properties of these products are given in Table 2. Table 2

*) at 275 ° C and a load of 5 kg

^ - * polymer blends:

Component αi: polyarylene ether AI component α ₂ : polystyrene-co-acrylonitrile A 4 component α ₃ : polyphenylene ether A 3 component ßi:

³⁰ polycaprolactam (polyamide 6, for example Ultramid B3 from BASF ^®), characterized by a viscosity number of 150 ml / g (determined according to DIN 53 727 on 0.5 wt -.% Solution in 96 wt -.% Sulfuric acid)

³⁵ Component γi: composition 1

Component 7 ₂ : Composition 3

Component γ ₃ : composition 4

40 component δi: rubber D

Production of polymer blends

"The components were mixed in a twin-screw extruder (ZSK 30 from Werner and Pfleiderer) at tempering temperatures in the range from 270 to 320 ° C. at a throughput of 10 k / h per 250 min, discharged and granulated. After drying, the granules were sprayed onto the test specimens. The compositions by weight of the polymer mixtures and the results of the mechanical tests are shown in Table 3.

Table 3

Table 3 cont.

Claims

claims

1. A method of making compositions containing

5 at least one thermoplastic polymer A and at least one polyamide B by dissolving the amorphous polymer A in at least one lactam b and, if desired, further polyamide-forming monomers b and then polymerizing the monomers b, characterized in that the monomers b 10 in the presence of 0.001 to 5 % By weight of water, based on the monomers b, polymerized.

2. The method according to claim 1, characterized in that the polymer A is a polyetherimide, a polyarylene ether

15 uses polyphenylene ether, a polystyrene, a styrene copolymer or an ethylene copolymer.

3. The method according to claim 1 or 2, characterized in that b ε-caprolactam is used as the lactam.

20th

4. The method according to any one of claims 1 to 3, characterized in that one carries out a molecular weight build-up in a further step.

25 5. The method according to claim 4, characterized in that the molecular weight build-up is achieved by extraction or tempering or a combination of these measures.

6. Compositions produced by a process according to 30 of one of claims 1 to 4.

7. Compositions according to claim 6, comprising at least one rubber, filler or reinforcing agent or further additive or mixtures of two or more thereof.

35

Use of the compositions according to claim 6 as compatibilizers in polymer mixtures.

9. polymer mixtures containing compositions according to claim 6.

10. Polymer mixtures according to claim 8, containing fillers or reinforcing agents.

45 11. Polymer mixtures according to claim 9, containing talc as a filler or reinforcing agent. ^'

12. Polymer mixtures according to one of claims 8 to 10, containing

α) 1 to 97% by weight of at least one polymer ß) compatible with polymer A) 1 to 97% by weight of at least one polymer γ) compatible with Polymaid B 2 to 80% by weight of the composition according to claim 6 δ) 0 to 40% by weight of impact-modifying rubbers ε) 0 to 60% by weight of fillers or reinforcing materials or their

Mixtures χ) 0 to ...% by weight of additives

13. Use of the compositions according to claim 6 or the polymer mixtures according to one of claims 7 to 11 for

Production of moldings, foils or fibers.

14. Moldings, films or fibers containing compositions according to claim 6.