Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
  • B29C48/05—Filamentary, e.g. strands
• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
  • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
  • C03C25/10—Coating
  • C03C25/24—Coatings containing organic materials
  • C03C25/26—Macromolecular compounds or prepolymers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/59—Polyamides; Polyimides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts

Definitions

• the present invention relates to a binder composition useful for the preparation of a thermoplastic composite. More specifically, the present invention relates to a binder material which when applied to a fiber substrate improves the compatibility and dispersion of the fiber in the thermoplastic resin matrix thereby providing an improved thermoplastic composite material with optimum mechanical and electrical performance.
• a binder material which when applied to a fiber substrate improves the compatibility and dispersion of the fiber in the thermoplastic resin matrix thereby providing an improved thermoplastic composite material with optimum mechanical and electrical performance.
• additives should be stable under processing and service conditions, they should not bleed or bloom, they should be inexpensive, and they should favorably alter the properties of the plastic host to provide some improved performance characteristic.
• thermoplastic composite as opposed to the more traditional thermoset composite, lies in the fact that melt processing techniques could be utilized to prepare the final composite material. Accordingly, as this field of thermoplastic composite materials developed, there became an ever growing need to develop new binder type materials which would improve the binding as between the fibers and the thermoplastic resin polymer host, as well as improve the dispersion of the fibers therein.
• a water soluble polymeric material that has been reported for some time, and which is now commercially available, is the polymer known as poly(2-ethyl-2- oxazoline).
• Poly(2-ethyl-2-oxazoline) is known to be heat stable (380 °C TGA in air), is available in a variety of molecular weights, is thermoplastic, non-ionic, non-toxic, and water soluble. It is sold under the tradename "AQUAZOL”, and is available from Polymer Chemistry Innovations, Inc., Tuscon, Arizona. It has been suggested for use in a variety of applications, such as adhesives, thickeners, greenware binders, and flocculates. A variety of U.S. Patents have therefore been issued which have explored the use of poly(2-ethyl-2-oxazoline) in one form or another.
• thermoplastic resins such as a polyether-imides, polycarbonates, polysulphones, polyesters, nylons, acrylonitrile-butadiene-styrene resins, and mixtures thereof.
• a composite comprising a fiber, a polymeric resin, and a poly-2-oxazoline polymer, wherein said fibers are dispersed in said composite material, and said fibers are coated with said poly-2-oxazoline polymer.
• the present invention comprises a method for preparing a plastic composite material comprising supplying fiber material, followed by preparation of an aqueous solution containing a water soluble binder polymer such as poly-2-oxazoline polymer, and drawing said fiber material through said aqueous solution and coating said fibers with said binder polymer, followed by drying and cutting said fibers to a desired length, and incorporating said coated fibers into a plastic resin to produce a plastic composite material.
• the present invention comprises more specifically a thermoplastic composite type material, which combines a poly-2-oxazoline coated fiber with a thermoplastic polymer resin material.
• the poly-2-oxazoline polymer is poly-2-ethyl-2-oxazoline polymer, which is available from Polymer Chemistry Innovations, Inc., and sold under the tradename "AQUAZOL".
• the poly-2-ethyl-2-oxazoline is coated onto the fiber material, and preferably, the poly-2-ethyl-2-oxazoline is present in the fiber at a level of about 1.5-40% (wt). Furthermore, after said coated fiber is incorporated into the thermoplastic resin, the coated fiber itself is preferably present at about 3-30% by weight of the final composite formulation.
• the resins that have been found particularly suitable for preparation of the composite herein, such resins preferably include the following thermoplastic materials: polyetherimides, polycarbonates, polysulphones, acrylic polymers, polyesters, nylons, acrylonitrile-butadiene styrene materials, and mixtures thereof.
• resins may also include any type of matrix polymeric resin material which when combined with a poly-2-oxazoline coated fiber material results in improved dispersion of the fiber in the polymeric resin matrix, and as noted, affords a substantially uniform dispersion of the fibers and improved mechanical and electrical properties.
• the fibers are more substantially uniformly dispersed in the thermoplastic resin composites disclosed herein. In other words, in the absence of the water soluble poly- 2-ethyl-2-oxazoline coating, the fibers were observed to clump together when incorporated into a theremoplastic resin matrix, thereby leading to a non-homogenous distribution of the fibers in the final composite material.
• the fibers when coated with the poly-2-ethyl-2-oxazoline as herein described, the fibers tended to wet-out much better when combined with the thermoplastic and thereby became substantially uniformly dispersed.
• the coated fibers herein demonstrate improved mechanical properties as opposed to uncoated fibers.
• ABS used is Diamond 7501 (high impact ABS).
• PC polycarbonate
• Apec DP9-93330- 1000 high heat PC
• Makrolon FCR-2458-1 112 general purpose PC
• Aquazol was mixed with water and surfactant to make a coating solution.
• NCG nickel coated graphite
• the treated NCG fiber was chopped V" long and tumbled with ABS and PC at different percentages.
• the commercial fiber was also used to reinforce ABS and PC for a reference.
• the tensile, flexural and impact tests were carried out.
• the electrical properties were also measured.
• Reinforced ABS Table II shows that aquazol treated NCG fiber is very compatible with ABS. When only poly-2-ethyl-2-oxazoline was mixed with ABS, both break stress and flexural modulus increased.
• the poly-2-ethyl-2-oxazoline treated fiber increased the break stress and flexural modulus more than the commercial fiber did.
• the impact test also shows that ABS reinforced with poly-2- ethyl-2-oxazoline treated fiber had the higher impact strength.
• Reinforced PC It is shown clearly in Table III and Table IV that the poly-2- ethyl-2-oxazoline treated fiber increased the properties of both Apec and Makrolon substantially. However, with the addition of commercial fiber, the properties of PC deteriorated. The impact test also shows the substantial deterioration of the impact strength for the commercial fiber reinforced PC. Electrical properties: With the commercial fiber and poly-2-ethyl-2- oxazoline treated fiber the surface resistivity and volume resistivity of ABS and PC are about the same.
• thermoplastic composite there is a difference in bonding strength as between polymer resin and fiber without the poly-2-ethyl-2- oxazoline coating, and resin and fiber with such coating, as measured by the above physical property tests.
• aqueous solution of the poly-2-ethyl-2-oxazoline which bath preferably contains a small amount of surfactant.
• a particularly preferred surfactant is sold under the tradename "Cyanamid Aersol OT", which is present in the solution at a level of about 0.2 % (wt).
• AQUAZOL 50 is placed into warm water (100 °F) followed by addition of surfactant.
• the solution is mixed and placed into a stainless steel trough, which is set-up for continuous fiber coating, as the fiber is passed through the solution at a controlled rate.
• a variety of variables can be adjusted to optimize coating or impregnation of binder onto the fibers. For example, one can select different molecular weights for the poly-2-ethyl-2-oxazoline, one can adjust the concentration of such polymer in the water bath, water temperature can be modified, and surfactant type and level can also be adjusted. By controlling such variables, one can readily promote different levels of binder coating on the fibers.
• binder on or in the fibers at a level of about 1.5-40% (wt), more preferably 15-18% (wt.).
• the residence time in the bath can be adjusted, which again would influence the amount of binder absorbed onto the fibers themselves.
• the fibers are then dried to remove water, and drying can be conveniently carried out by hot air or infrared type heating.
• the fibers can be promptly introduced into a cross-head extruder and over-extruded with a thermoplastic resin.
• fiber concentrate i.e., a pellet containing thermoplastic resin and fiber.
• fiber concentrate that is more conveniently handled, and such fiber concentrate then can be mixed with additional thermoplastic resin to the final let-down value of about 15-18 % (wt.) noted above.
• fibers can be coated in accordance with the present invention.
• fibers such as glass, carbon, nickel plated carbon, aromatic polyamide fiber (e.g., KEVLAR), and stainless steel, can be coated or become impregnated with the water soluble poly-2-ethyl-2-oxazoline binder disclosed herein.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Textile Engineering (AREA)
• Organic Chemistry (AREA)
• Mechanical Engineering (AREA)
• General Life Sciences & Earth Sciences (AREA)
• General Chemical & Material Sciences (AREA)
• Geochemistry & Mineralogy (AREA)
• Manufacturing & Machinery (AREA)
• Health & Medical Sciences (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Reinforced Plastic Materials (AREA)

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• 2000
  • 2000-11-13 WO PCT/US2000/031173 patent/WO2001034385A1/en not_active Application Discontinuation
  • 2000-11-13 EP EP00980366A patent/EP1265745A4/de not_active Withdrawn

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