EP2989165A1

EP2989165A1 - Thermosetting materials having improved fracture toughness

Info

Publication number: EP2989165A1
Application number: EP14721467.0A
Authority: EP
Inventors: Quentin Pineau; Maho Yasuda
Original assignee: Arkema France SA
Current assignee: Arkema France SA
Priority date: 2013-04-22
Filing date: 2014-04-10
Publication date: 2016-03-02
Also published as: WO2014174176A1; FR3004719B1; US20160068675A1; FR3004719A1; JP2016520686A

Abstract

The present invention relates to a composition including, by weight, the total being 100 %: 50 to 99 % of a curable resin and of a curing agent in a molar ratio in the range of 1/5 to 5/1, and 1 to 50 % of a mixture: of a polyamide which includes at least one monomer resulting from the condensation of a diacid and of a diamine of formula (1) where: R₁ is H or -Z1-NH2 and Z1 is an alkyl, a cycloalkyl or an aryl having up to 15 carbon atoms, and R₂ is H or -Z2-NH2 and Z2 is an alkyl, a cycloalkyl or an aryl having up to 15 carbon atoms, R₁ and R₂ being either identical or different, and of an oligomer made from butadiene and acrylonitrile which are terminated by carboxyl functions or by amine functions, such as the reactive rubbers CTBN or ATBN; the polyamide and the oligomer being present in respective proportions of 1/10 to 10/1 by weight.

Description

ENHANCED RUPTURE THERMODY MATERIALS

[Field of the invention]

The present invention relates to thermoset materials having improved fracture toughness, and which have good properties of resistance to impact, stiffness and glass transition temperature (hereinafter Tg).

Two main definitions of "fracture toughness" are generally used: the critical energy release rate and the critical stress intensity factor.

- The critical stress intensity factor, K1 C (in MPa / Vm), defines for a material the critical value of stress beyond which the rupture occurs. The stress intensity factor, K1 C, is a measure of the applied stress associated with the size of the cracks.

- The rate of critical energy restitution, G1 C (in J / m ² ), is defined as the critical energy required for the propagation of a crack per unit area. If a stress on a sample exceeds the critical energy, a fracture occurs.

A thermoset material is defined as being formed of polymer chains of variable length interconnected by covalent bonds so as to form a three-dimensional network. The thermoset materials may be obtained for example by reaction of a thermosetting resin such as an epoxy with an amine type hardener. Thermoset materials have many interesting properties, especially for use as structural adhesives or as a matrix for composite materials or in applications for protecting electronic components.

Preferably, the aforementioned applications require thermoset materials which ideally have the following properties:

- Tg greater than 170 ° C (DMA, ISO6721 -5)

- Flexural modulus greater than 2 GPa (ISO 178)

- Traction module greater than 2 GPa (ISO 527) - Impact resistance (or "impact resistance") - notched shock - more than 2 KJ / m2 (ISO 179 - 1)

- Impact resistance - Chock Charpy unscored - greater than 20 KJ / m2 (ISO 179 - 1)

and for the invention, it is sought in particular to improve K 1 C and G 1 C (ASTMD 50 45), to attain K 1 C values preferably greater than 1 MPa / Vm, and G 1 C values greater than 400 J / m 2 , guaranteeing excellent fracture toughness of thermoset materials.

[The technical problem]

Among the thermosets, the epoxy materials have a high crosslinking density, which gives them a high Tg which gives the material excellent thermomechanical properties. The higher the crosslinking density, the higher the Tg of the material and therefore the better the thermomechanical properties: the higher the temperature limit of use of the material. For many applications, the properties of fracture toughness and impact strength (or withstand) of current epoxy-based materials are insufficient. While Epoxy materials are inherently difficult to impact-proof, the most difficult are the high Tg epoxy materials. Many studies have been devoted to the impact strengthening of these high Tg epoxy materials and these studies conclude that the addition of rubber to a high Tg epoxy material has no reinforcing effect. By way of example of such materials, mention may be made of the DGEBA / DDS systems (Tg = 220 ° C.) in which DDS denotes diamino diphenyl sulphone or the DGEBA / MCDEA systems (Tg = 180 ° C.) in which MCDEA designates the 4 , 4'-methylenebis (3-chloro-2,6-diethylaniline). In the above materials DGEBA denotes the diglycidyl ether of bisphenol A.

For example, the addition of reactive rubbers, such as ATBN, CTBN, to epoxy matrices has been tested before. These abbreviations mean:

CTBN: Carboxyl terminated random copolymer of butadiene and acrylonitrile. ATBN: Amino terminated random copolymer of butadiene and acrylonitrile. These products are oligomers based on butadiene and acrylonitrile terminated either by carboxyl functions or by amine functions. Butadiene has a very low Tg which is favorable for obtaining a good impact strength but it is not miscible with epoxy resins. A certain percentage of acrylonitrile is copolymerized with butadiene so that the product formed is initially miscible with the epoxy resin and thus can be readily incorporated therein. P. Lovell (Macromol Symp., 92, Pages 71-81, 1995) and A. Mazouz et al. Polymer Material Science Engineering, 70, p17, 1994 report that at the end of the crosslinking reaction part of the functional oligomer forms elastomeric particles and a non-negligible part remains incorporated in the matrix. This results in a lowering of the Tg of the material obtained compared to the pure epoxy network which is not desirable for applications requiring good thermomechanical properties. The elastomer domains formed have a large size conventionally between 0.5 microns and 5 microns. The reinforcement obtained is not satisfactory.

WO03063572 discloses homogeneous compositions comprising a curable (or crosslinkable) resin and a polyamide having piperazine units. It is not necessary to add a solvent and the composition before crosslinking is homogeneous, so it can be easily injected or used to coat surfaces. In addition, if the polyamide having piperazine units has sufficient functions to crosslink the thermosetting resin then it is not necessary to add a hardener. According to this document, said compositions would make it possible to obtain a thermoset material of very good impact resistance. In addition, the usual thermomechanical properties of thermosets such as high Tg and flexural modulus would be retained.

In practice, even if the thermosetting matrix retains its rigidity and if its impact resistance is improved, it is found that this is not always the case with other properties such as fracture toughness, and the Tg decreases. Indeed, the fracture toughness of the thermoset matrix is not sufficient, and is not improved by incorporation of polyamide in these compositions. Similarly, the Tg in these compositions is greatly reduced (see Table 2 of the examples), by polyamide incorporation due to the good miscibility thereof with the thermosetting matrix.

Furthermore, EP 0232225 discloses compositions comprising an epoxy resin, an acrylic oligomer, an amine compound and a nitrile rubber having amino terminations. The fracture toughness (K1 C and G1 C) is not specified in this document.

The present invention therefore aims to provide thermoset compositions with improved fracture toughness, and which have parallel properties of impact resistance, stiffness and Tg meeting the predefined requirements.

The Applicant has now found that the combined use of polyamide and oligomer selected by the invention in a thermoset composition, allowed to obtain thermoset compositions with significantly improved fracture toughness, while retaining excellent strength properties. impact, stiffness and Tg, compatible with use as structural adhesives or as a matrix for composite materials or in electronic component protection applications.

[Description of the invention]

The subject of the present invention is therefore a composition comprising, by weight, the total being 100%:

10 to 99% of hardenable resin and hardener in a molar ratio in the range of 1/5 to 5/1, and

- 1 to 90% of a mixture:

polyamide which comprises at least one monomer resulting from the condensation of a diacid and a diamine of formula (1) below: R ₂ NN Ri

in which :

R 1 represents H or -Z 1 -NH 2 and Z 1 represents alkyl, cycloalkyl or aryl having up to 15 carbon atoms, and F¾ represents H or -Z 2 -NH 2 and Z 2 represents alkyl, cycloalkyl or aryl having up to with 15 carbon atoms, Ri and F¾ being identical or different, and

oligomers based on butadiene and acrylonitrile terminated either by carboxyl functions or by amine functions, such as CTBN or ATBN reactive rubbers;

polyamide and oligomer being in respective proportions by weight of 1/10 to 10/1.

The subject of the present invention is in particular the use of a mixture of polyamide and oligomer in a thermoset matrix to improve its fracture toughness as determined according to ASTMD5045,

the thermoset matrix comprising a curable resin and a hardener with a molar ratio in the range of 1/5 to 5/1,

said polyamide comprising at least one monomer resulting from the condensation of a diacid and a diamine of formula (1) below:

in which :

R 1 represents H or -Z 1 -NH 2 and Z 1 represents alkyl, cycloalkyl or aryl having up to 15 carbon atoms, and R 2 represents H or -Z 2 -NH 2 and Z 2 represents alkyl, cycloalkyl or aryl having up to 15 carbon atoms, Ri and R2 may be the same or different, and

the oligomer being based on butadiene and acrylonitrile terminated either by carboxyl functions or by amine functions, such as the CTBN or ATBN reactive rubbers; and

said mixture representing from 1 to 90% by weight, relative to the total weight of the thermoset matrix, and the polyamide and the oligomer being in respective proportions by weight of 1/10 to 10/1, preferably of 1/5 to 5/1.

Advantageously, the composition comprises from 50% to 99% by weight of curable resin and hardener, preferably from 50% to 90% by weight of curable resin and hardener.

Advantageously, the composition comprises from 1 to 50% by weight of an oligomeric polyamide mixture, preferably from 10 to 50% by weight of an oligomeric polyamide mixture.

Advantageously, the composition comprises from 50% to 90% by weight of curable resin and hardener and from 10 to 50% of oligomeric polyamide mixture.

The term "oligomer" in the oligomeric polyamide mixture denotes a compound having a molar mass of Mn between 1000 and 5000.

For the purposes of the invention, the term "curable resin" means a resin chosen in particular from cyanoacrylates, precursors of bismaleimides and carriers of oxirane functional groups such as epoxy resins.

Among the cyanoacrylates, mention may be made of the 2-cyanoacrylic ester of formula CH2 = C (CN) COOR with various possible R groups.

Among the precursors of the bismaleimides include benzophenone dianhydride. The thermodide formulations of bismaleimide type are, for example:

methylenedianiline + benzophenone dianhydride + nadic imide

methylenedianiline + benzophenone dianhydride + phenylacetylene

methylenedianiline + maleic anhydride + maleimide.

Advantageously, the curable resin is an epoxy resin. By epoxy resin, hereinafter referred to as E, is meant any organic compound having at least two functions of oxirane type, polymerizable by ring opening. The term "epoxy resins" refers to all usual epoxy resins which are liquid at room temperature (23 ° C.) or at a higher temperature. These epoxy resins can be monomeric or polymeric on the one hand, aliphatic, cycloaliphatic, heterocyclic or aromatic on the other hand. By way of examples of such epoxy resins, mention may be made of diglycidyl ether of resorcinol, diglycidyl ether of bisphenol A, triglycidyl p-amino phenol, diglycidyl ether of bromo-bisphenol F, triglycidyl ether of m-amino phenol, tetraglycidyl methylene dianiline, (t hydroxyphenyl) methane triglycidyl ether, novolac phenol-formaldehyde polyglycidyl ethers, orthocresol novolac polyglycidyl ethers and tetraphenyl ethane tetraglycidyl ethers. Mixtures of at least two of these resins may also be used.

Epoxy resins having at least 15 oxirane functions per molecule and more particularly epoxy resins containing between 2 and 4 oxirane functions per molecule are preferred. Epoxy resins having at least one aromatic ring, such as diglycidyl ethers of bisphenol A, are also preferred.

By hardener in the sense of the invention generally means hardeners epoxy resins that react at room temperature or at temperatures above room temperature. By way of nonlimiting examples, mention may be made of:

• acid anhydrides, including succinic anhydride,

Aromatic, cycloaliphatic or aliphatic polyamines, of which diamino diphenyl sulphone (DDS) or methylene dianiline or 4,4'-methylenebis (3-chloro-2,6-diethylaniline) (MCDEA),

• Dicyandiamide and its derivatives.

• Imidazoles

• Polycarboxylic acids

• Polyphenols The skilled person easily determines the amount of hardener relative to the amount of curable resin taking into account the available functions possibly carried by the polyamide (or copolymer). The higher the proportion of polyamide (or copolymer), the better the toughness of the material (or resistance to cracking).

Advantageously, the resin is an epoxy resin and the optional hardener is a polyamine.

Advantageously, the polyamide contains at least 50% by weight of units consisting of the diamine residues of formula (1) condensed with the diacid.

For the purposes of the invention, polyamide (homopolyamide or copolyamide) is understood to mean the products of condensation of lactams, amino acids and / or diacids with diamines and, as a rule, any polymer formed by units or monomers connected to each other by amide groups, which comprise at least one monomer resulting from the condensation of a diacid and a diamine of formula (1) below:

in which :

R 1 represents H or -Z 1 -NH 2 and Z 1 represents alkyl, cycloalkyl or aryl having up to 15 carbon atoms, and

R2 represents H or -Z2-NH2 and Z2 represents an alkyl, a cycloalkyl or an aryl having up to 15 carbon atoms,

Ri and R2 may be the same or different.

The term "monomer" in the present description of polyamides should be understood as "repetitive unit". The case where a repeating unit of the polyamide consists of the combination of a diacid with a diamine is particular. It is considered that it is the combination of a diamine and a diacid, that is to say the diamine.diacide couple (in equimolar quantity), which corresponds to the monomer. This is explained by the fact that, individually, the diacid or the diamine is only a structural unit, which is not enough on its own to polymerize. In the case where the polyamides according to the invention comprise at least two different monomers, called "co-monomers", that is to say at least one monomer and at least one comonomer (monomer different from the first monomer), they comprise a copolymer such as abbreviated copolyamide COPA.

By copolyamide (abbreviated as COPA) is meant the products of polymerization of at least two different monomers chosen from:

amino-acid or aminocarboxylic acid monomers, and preferably alpha, omega-aminocarboxylic acids;

- Lactam type monomers having from 3 to 18 carbon atoms on the main ring and may be substituted;

the "diamine diacid" type monomers resulting from the reaction between an aliphatic diamine having from 4 to 36 carbon atoms, preferably from 4 to 18 carbon atoms and a dicarboxylic acid having from 4 to 36 carbon atoms, preferably from 4 to 18 carbon atoms; and

their mixtures with monomers with a different carbon number in the case of mixtures between an amino acid type monomer and a lactam type monomer.

Amino acid type monomers:

By way of examples of alpha, omega-amino acids, mention may be made of those having from 4 to 18 carbon atoms, such as aminocaproic acid, 7-aminoheptanoic acid, 1-aminoundecanoic acid, N-heptyl-1 1 -aminoundecanoic acid and 12-aminododecanoic.

Monomers of the lactam type:

Examples of lactams include those having from 3 to 18 carbon atoms on the main ring and may be substituted. Examples that may be mentioned include β, β-dimethylpropriolactam, α, α-dimethylpropriolactam, amylolactam, caprolactam also known as lactam 6, capryllactam also known as lactam 8, oenantholactam and lauryllactam, also known as lactam 12.

Monomers of the "diamine.diacide" type: As examples of dicarboxylic acid, there may be mentioned acids having 4 and 36 carbon atoms. Mention may be made, for example, of adipic acid, sebacic acid, azelaic acid, suberic acid, isophthalic acid, butanedioic acid, 1,4-cyclohexyldicarboxylic acid, terephthalic acid, sodium or lithium salt of sulphoisophthalic acid, dimerized fatty acids (these dimerized fatty acids have a dimer content of at least 98% and are preferably hydrogenated) and dodecanedioic acid HOOC- (CH2) 10- COOH, and tetradecanedioic acid.

More particularly, dimerized fatty acids or dimerized fatty acids are understood to mean the product of the fatty acid dimerization reaction (generally containing 18 carbon atoms, often a mixture of oleic and / or linoleic acid). It is preferably a mixture comprising from 0 to 15% of C18 monoacids, from 60 to 99% of C36 diacids, and from 0.2 to 35% of C54 triacids or polyacids or more.

By way of example of a diamine of formula (1), mention may be made of the diamines in which R 1 and R 2 denote H, that is to say piperazine, and those in which R 1 is H and R 2 is -CH 2 -CH 2 NH 2, i.e. aminoethylpiperazine. The polyamide of the composition of the invention preferably comprises at least one diamine of formula (1) chosen from piperazine (abbreviated "Pip"), aminoethylenepiperazine, and mixtures thereof.

By way of example of a diamine which can be used in addition to that of formula (1), mention may be made of aliphatic diamines having from 4 to 36 atoms, preferably from 4 to 18 atoms, which may be aryl and / or saturated cyclic. By way of examples, mention may be made of hexamethylenediamine, tetramethylenediamine, octamethylenediamine, decamethylene diamine, dodecamethylenediamine, 1,5 diaminohexane, 2,2,4-trimethyl-1,6-diaminoethylenediamine. hexane, diamine polyols, isophorone diamine (IPD), methyl pentamethylenediamine (MPMD), bis (aminocyclohexyl) methane (BACM), bis (3-methyl-4-aminocyclohexyl) methane (BMACM), methaxylyenediamine, and bis-p-aminocyclohexylmethane.

By way of other examples of "diamine.diacid" type monomers, mention may be made of those resulting from the condensation of hexamethylenediamine with a C6 to C36 diacid, especially the monomers: 6.6, 6.10, 6.1 1, 6.12, 6.14, 6.18. Mention may be made of the monomers resulting from the condensation of decanediamine with a C6 to C36 diacid, especially the monomers: 10.10, 10.12, 10.14, 10.18.

Mention may also be made of copolyamides resulting from the condensation of at least one alpha, omega-aminocarboxylic acid (or a lactam), at least one diamine of formula (1) and at least one dicarboxylic acid. Mention may also be made of the copolyamides resulting from the condensation of a diamine of formula (1) with an aliphatic dicarboxylic acid and of at least one other monomer chosen from the aliphatic diamines different from the preceding one and the aliphatic diacids different from the preceding one.

Advantageously, the PA used in the composition according to the invention is obtained at least partially from bio-resourced raw materials.

Raw materials of renewable origin or bio-sourced raw materials are materials that include biofouled carbon or carbon of renewable origin. In fact, unlike materials made from fossil materials, materials made from renewable raw materials contain 14C. "Renewable carbon content" or "bio-resourced carbon content" is determined in accordance with ASTM D 6866 (ASTM D 6866-06) and ASTM D 7026 (ASTM D 7026-04).

As examples of amino acids of renewable origin, there may be mentioned: 11-aminoundecanoic acid produced from castor oil for example, 12-aminododecanoic acid produced from castor oil by for example, 10-aminodecanoic acid produced from decylenic acid obtained by metathesis of oleic acid for example, 9-aminononanoic acid produced from oleic acid for example.

As examples of diacids of renewable origin, one can cite, according to the number x of carbons of the molecule (Cx):

C4: succinic acid from glucose, for example;

C6: adipic acid from glucose for example;

C7: heptanedioic acid from castor oil; - C9: azelaic acid from oleic acid (ozonolysis) for example;

C10: sebacic acid from castor oil for example;

C1 1: undecanedioic acid from castor oil;

- C12: dodecanedioic acid from biofermentation of dodecanoic acid = lauric acid (rich oil: palm kernel oil and coconut) for example;

- C13: brassylic acid from erucic acid (ozonolysis) found in rapeseed, for example;

- C14: tetradecanedioic acid by biofermentation of myristic acid (rich oil: palm kernel oil and coconut) for example;

C16: hexadecanedioic acid by biofermentation of palmitic acid (mainly palm oil) for example;

- C18: octadecanedioic acid obtained by biofermentation of stearic acid (a little in all vegetable oils but predominant in animal fats) for example;

C20: eicosanedioic acid obtained by biofermentation of arachidic acid (predominant in rapeseed oil) for example;

C22: docosanedioic acid obtained by metathesis of undecylenic acid (castor oil) for example

- C36: Fatty acid dimer derived from by-products of softwoods transfomed by the Kraft process.

By way of examples of diamines of renewable origin, one can cite, as a function of the number x of carbons of the molecule (Cx):

C4: butanediamine obtained by amination of succinic acid;

C5: pentamethylene diamine (from lysine);

and so on for the diamines obtained by amination of diacids of renewable origin previously seen.

Advantageously, the polyamide results from the condensation:

At least one diacid chosen from saturated aliphatic diacids containing from 2 to 36 carbon atoms, preferably from 2 to 18 carbon atoms,

At least one diamine of formula (1), At least one alpha omega amino carboxylic acid or a lactam. Preferably the polyamide results from the condensation:

At least one diacid chosen from saturated aliphatic diacids containing from 6 to 12 carbon atoms,

At least one diamine of formula (1),

At least one alpha omega amino carboxylic acid or a lactam. By way of example, mention may be made of polyamides which result from condensation:

One or two diacids chosen from saturated aliphatic diacids containing from 6 to 12 carbon atoms,

A diamine of formula (1), advantageously piperazine,

An alpha omega amino carboxylic acid or a lactam, advantageously chosen from 1-amino-1-undecanoic acid and lauryllactam.

Advantageously, the polyamide comprises from 10 to 100 mol%, preferably from 40 to 100 mol%, preferably from 50 to 100 mol%, preferably from 60 to 100 mol%, of at least one monomer chosen from: pip. 9, Pip.10, Pip.12, Pip.14, Pip.18, Pip.36, AEP.6, AEP.9, AEP.10, AEP.12, AEP.14, AEP.18, AEP.36, and mixtures thereof, based on the total number of moles of polyamide in the composition.

Advantageously, the polyamide also comprises at least one of the following monomers: 4.6, 4.T, 5.4, 5.9, 5.10, 5.12, 5.13, 5.14, 5.16, 5.18, 5.36, 6, 6.4, 6.9, 6.10, 6.12, 6.13, 6.14, 6.16, 6.18, 6.36, 6, 9, 10.4, 10.9, 10.10,

10.12, 10.13, 10.14, 10.16, 10.18, 10.36, 10.T, 11, 12, 12.4, 12.9, 12.10, 12.12,

12.13, 12.14, 12.16, 12.18, 12.36, 12.T, and mixtures thereof in alloy or copolyamide form.

Preferably, the polyamide used in the present invention comprises at least one homopolyamide chosen from PA Pip.9, PA Pip.10, PA Pip.12, PA Pip.14, PA Pip.18, PA Pip.36, PA AEP.6 , PA AEP.9, PA AEP.10, PA AEP.12, PA AEP.14, PA AEP.18, PA AEP.36, and mixtures thereof and / or at least one copolyamide chosen from: PA Pip.9 / Pip .12 / 1 1, PA 6 / Pip.12 / 12, PA 6.10 / Pip.10 / Pip.12, PA Pip.12 / 12, PA Pip.10 / 12, PA Pip.10 / 1 1 / Pip. 9, and especially those whose mass ratios are defined above, and mixtures of these copolyamides.

One or more of the following copolyamides are preferably used in the thermoset composition or material of the present invention (the molar ratios of which are indicated in parentheses)

PA Pip.9 / Pip.12 / 1 1 mass ratio 15/70/15 (16/63/21);

PA 6 / Pip.12 / 12 of 30/20/50 mass ratio (46/10/44);

PA 6.10 / Pip.10 / Pip.12 of mass ratio 20/40/40 (40/31/29);

PA Pip.12/12 ratio of mass ratio 35/65 (25/75)

PA Pip.10 / 12 Mass Ratio 72/28 (64/36)

PA Pip.10 / 1 1 / Mass ratio pip.9 65/30/5 (57/38/5)

Examples of copolyamides that may be mentioned include those marketed under the name Platamid® and Platamid® Rnew by ARKEMA, Vestamelt® by Evonik, and Griltex® by EMS.

According to another form of the invention, the polyamide is a copolymer with polyamide blocks and polyether blocks, the polyamide blocks resulting from the condensation of at least one diacid chosen from the preceding diacids and at least one diamine of formula (1) . That is, the polyamide blocks of the polyamide block and polyether block copolymer are the polyamide described in the previous paragraph.

The polyamide block and polyether block copolymers result from the copolycondensation of polyamide sequences with reactive ends with polyether sequences with reactive ends, such as, inter alia:

1) Polyamide sequences with diamine chain ends with polyoxyalkylene sequences with dicarboxylic chain ends.

2) Polyamide sequences with dicarboxylic chain ends with polyoxyalkylene sequences with diamine chain ends obtained by cyanoethylation and hydrogenation of aliphatic dihydroxylated polyoxyalkylene aliphatic sequences called polyether diols. 3) Polyamide sequences with dicarboxylic chain ends with polyetherdiols, the products obtained being, in this particular case, polyetheresteramides.

The polyamide sequences with carboxylic chain ends are obtained by using a diacid chain limiter, that is to say that the condensation of the diamine of formula (1) and of the diacid with an excess of this diacid or by adding another diacid. The polyamide sequences with diamine chain ends are obtained by using a diamine chain limiter, that is to say that the condensation of the diamine of formula (1) and of the diacid with an excess of this diamine or by adding another diamine. The polyamide sequences may comprise other units selected from alpha omega amino carboxylic acids and diamines different from the diamine of the formula (1). Examples of such monomers have been mentioned above.

Advantageously, the polyamide block and polyether block copolymer contains at least 50% by weight of units consisting of the diamine residues of formula (1) condensed with the diacid.

The polyether blocks can represent 5 to 85% by weight of the polyamide and polyether block copolymer. The polyether blocks consist of alkylene oxide units. These units may be, for example, ethylene oxide units, propylene oxide or tetrahydrofuran units (which leads to polytetramethylene glycol linkages). PEG blocks are thus used, that is to say those consisting of ethylene oxide units, PPG blocks, ie those consisting of propylene oxide units and PTMG blocks, ie those consisting of tetramethylene glycol units. also called polytetrahydrofuran. It is possible to use PEG blocks or blocks obtained by oxyethylation of bisphenols, such as, for example, bisphenol A. These latter products are described in patent EP 613 919.

The polyether blocks may also consist of ethoxylated primary amines. These blocks can also be used. By way of example of ethoxylated primary amines, mention may be made of the products of formula: H (OCH ₂ CH ₂ ) _m - N (CH ₂ CH ₂ 0) _n - H

(CH ₂ ) x CH ₃

in which m and n are between 1 and 20 and x between 8 and 18. These products are commercially available under the NORAMOX® brand from CECA and under the GENAMIN® brand from CLARIANT.

The amount of polyether blocks in these polyamide block and polyether block copolymers is advantageously from 10 to 70% by weight of the copolymer and preferably from 35 to 60%.

The polyetherdiol blocks are either used as such and copolycondensed with polyamide blocks having carboxylic ends, or they are aminated to be converted into polyether diamines and condensed with polyamide blocks having carboxylic ends. They can also be mixed with polyamide precursors and a diacid chain limiter to make the polyamide block and polyether block polymers having statistically distributed patterns.

The molar mass in number Mn of the polyamide sequences is between 500 and 10,000 and preferably between 500 and 4000 except for the polyamide blocks of the second type. The mass Mn of the polyether sequences is between 100 and 6000 and preferably between 200 and 3000.

These polymers with polyamide blocks and polyether blocks, whether from the copolycondensation of previously prepared polyamide and polyether blocks or from a one-step reaction, have, for example, an intrinsic viscosity of between 0.8 and 2.5 measured in metacresol. at 250 ° C for an initial concentration of 0.8 g / 100 ml.

With regard to their preparation, the copolymers of the invention may be prepared by any means for hanging the polyamide blocks and the polyether blocks. In practice, essentially two methods are used, one said in 2 steps, the other in one step. In the two-step process, the polyamide blocks are first produced and then, in a second step, the polyamide blocks and the polyether blocks are bonded. In the one-step process, the polyamide precursors, the chain limiter and the polyether are mixed. A polymer having essentially polyether blocks, polyamide blocks of very variable length, but also the various reagents reacted randomly are then obtained which are distributed randomly (statistically) along the polymer chain. Whether in one or two steps it is advantageous to operate in the presence of a catalyst. The catalysts described in US Pat. Nos. 4,331,786, 4,145,475, 4,195,155, 4,839,441, 4,884,014, 4,230,838 and 4,332,920 can be used. step is also manufactured polyamide blocks. This is why it was written at the beginning of this paragraph that the copolymers of the invention could be prepared by any means of hanging polyamide blocks and polyether blocks.

Processes of preparation are now described in detail in which the polyamide blocks are carboxyl-terminated and the polyether is a polyetherdiol.

The two-step process consists firstly in preparing the polyamide blocks with carboxylic ends and then in a second step in adding the polyether and a catalyst. The preparation reaction of the carboxylic-terminated polyamide is usually between 180 and 300 ° C, preferably 200 to 260 ° C. The pressure in the reactor is between 5 and 30 bar, it is maintained for about 2 hours. The pressure is slowly reduced by putting the reactor at atmospheric pressure and then the excess water is distilled for example in one or two hours.

The polyamide with carboxylic acid ends having been prepared, the polyether and a catalyst are then added. The polyether can be added in one or more times, as can the catalyst. According to one advantageous form, the polyether is firstly added, the reaction of the OH ends of the polyether and the COOH ends of the polyamide begins with ester bond formation and water elimination; the water is removed as much as possible from the reaction medium by distillation and then the catalyst is introduced to complete the binding of the blocks polyamide and polyether blocks. This second step is carried out with stirring preferably under a vacuum of at least 5 mmHg (650 Pa) at a temperature such that the reagents and copolymers obtained are in the molten state. For example, this temperature can be between 100 and 400 ° C and most often 200 and 300 ° C. The reaction is monitored by measuring the torque exerted by the molten polymer on the stirrer or by measuring the electrical power consumed by the stirrer. The end of the reaction is determined by the value of the target torque or power. The catalyst is defined as any product that facilitates the bonding of polyamide blocks and polyether blocks by esterification. The catalyst is advantageously a derivative of a metal (M) chosen from the group formed by titanium, zirconium and hafnium.

By way of example of a derivative, mention may be made of tetraalkoxides which correspond to the general formula M (OR) 4, in which M represents titanium, zirconium or hafnium, and R, which may be identical or different, denote linear alkyl groups. or branched, having from 1 to 24 carbon atoms.

The C1-C24 alkyl radicals chosen from among the R radicals of the tetraalkoxides used as catalysts in the process according to the invention are, for example, those such as methyl, ethyl, propyl, isopropyl, butyl, ethylhexyl, decyl, dodecyl or hexadodecyl. The preferred catalysts are tetraalkoxides for which the R radicals, which may be identical or different, are C1-C4 alkyl radicals. Examples of such catalysts are especially Z _r (OC2H5) 4, Z _r (O-isoC3H7) 4, Z _r (OC4Hg) 4,

Z _r (OC ₅ H _{1 1)} _4, Z _r (OC ₆ H _{1 3)} _4, H _f (OC ₂ H ₅₎ 4, H _f (OC ₄ H ₉₎ 4, H _f (O-ISOC ₃ H ₇ ) 4.

The catalyst used in this process according to the invention may consist solely of one or more of the tetraalkoxides of formula M (OR) 4 defined previously. It can also be formed by the combination of one or more of these tetraalkoxides with one or more alkali or alkaline-earth alkoxides of formula (R 1) pY in which R 1 denotes a hydrocarbon residue, advantageously a C 1 alkyl residue. at C24, and preferably at C1 to C4,

Y represents an alkali or alkaline earth metal and p is the valence of Y. The amounts of alkali or alkaline earth alkoxide and zirconium or hafnium tetraalkoxides which are combined to form the mixed catalyst can vary within wide limits. However, it is preferred to use amounts of alcoholate and tetraalkoxides such that the molar proportion of alkoxide is substantially equal to the molar proportion of tetraalkoxide.

The proportion by weight of catalyst, that is to say of the tetraalkoxides or when the catalyst does not contain alkali or alkaline earth alkoxide or all of the tetraalkoxides and alkali or alkaline alkoxide or alcoholates when the catalyst is formed by the combination of these two types of compounds, preferably varies from 0.01 to 5% by weight of the mixture of the polyamide dicarboxylic with polyoxyalkylene glycol, and is preferably between 0.05 and 2% of this weight.

By way of example of other derivatives, mention may also be made of the salts of the metal (M), in particular the salts of (M) and of an organic acid and the complex salts between the oxide of (M) and / or (M) hydroxide and an organic acid. Advantageously, the organic acid may be formic acid, acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, caprylic acid, lauroyl acid, myristic, palmitic acid, stearic acid, oleic acid, linoleic acid, linolenic acid, cyclohexane carboxylic acid, phenylacetic acid, benzoic acid, salicylic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, maleic acid, fumaric acid, phthalic acid and crotonic acid. Acetic and propionic acids are particularly preferred. Advantageously M is zirconium. These salts may be called zirconyl salts. Applicant without being bound by this explanation think that these salts of zirconium and an organic acid or complex salts mentioned above release ZrO ⁺⁺ during the process. The product sold under the name of zirconyl acetate is used. The quantity to be used is the same as for the M (OR) 4 derivatives. This process and these catalysts are described in US Patents 4,332,920, US 4,230,838, US 4,331,786, US 4,252,920, JP 07145368A, JP 06287547A, and EP 613919.

As regards the one-step process, all the reagents used in the process are mixed in two stages, that is to say the polyamide precursors, the polyether and the catalyst. These are the same reagents and the same catalyst as in the two-step process described above.

The copolymer has essentially the same polyether blocks, the same polyamide blocks, but also a small portion of the various reagents reacted randomly that are randomly distributed along the polymer chain.

The reactor is closed and heated with stirring as in the first step of the two-step process described above. The pressure is between 5 and 30 bar. When it no longer evolves, the reactor is reduced under reduced pressure while maintaining vigorous stirring of the molten reactants. The reaction is followed as above for the two-step process.

The catalyst used in the one-step process is preferably a salt of the metal (M) and an organic acid or a complex salt between the (M) oxide and / or the (M) hydroxide and an acid. organic.

Processes of preparation are now described in detail in which the polyamide blocks are at carboxyl ends and the polyether is a polyetherdiamine.

The two-step process consists firstly in preparing the polyamide blocks with carboxylic ends by condensation of the polyamide precursors in the presence of a chain-limiting dicarboxylic acid, then in a second step in adding the polyether and optionally a catalyst.

The reaction is usually between 180 and 300 ° C, preferably 200 to 260 ° C the pressure in the reactor is between 5 and 30 bar, it is maintained about 2 hours. The pressure is slowly reduced by putting the reactor at atmospheric pressure and then the excess water is distilled for example in one or two hours. The polyamide with carboxylic acid ends having been prepared is then added polyether and optionally a catalyst. The polyether can be added in one or more times, as can the catalyst. According to an advantageous form, the polyether is first added, the reaction of the NH ₂ ends of the polyether and the COOH ends of the polyamide begins with the formation of amide bonding and the elimination of water; As much water as possible is removed from the reaction medium by distillation and then the optional catalyst is introduced to complete the bonding of the polyamide blocks and the polyether blocks. This second step is carried out with stirring preferably under a vacuum of at least 5 mmHg (650 Pa) at a temperature such that the reagents and copolymers obtained are in the molten state. For example, this temperature can be between 100 and 400 ° C and most often 200 and 300 ° C. The reaction is monitored by measuring the torque exerted by the molten polymer on the stirrer or by measuring the electrical power consumed by the stirrer. The end of the reaction is determined by the value of the target torque or power. The catalyst is defined as any product that facilitates the bonding of polyamide blocks and polyether blocks. Those skilled in the art prefer protic catalysis.

As regards the one-step process, all the reagents used in the process are mixed in two stages, that is to say the polyamide precursors, the chain-limiting dicarboxylic acid, the polyether and the catalyst. These are the same reagents and the same catalyst as in the two-step process described above.

The reactor is closed and heated with stirring as in the first step of the two-step process described above. The pressure is between 5 and 30 bar. When it no longer evolves, the reactor is placed under reduced pressure while maintaining vigorous stirring of the reagents melted. The reaction is followed as above for the two-step process.

The proportions by weight in the composition or thermoset matrix according to the invention are:

50 to 90%, preferably 50 to 85%, preferably 50 to 80%, hardenable resin and hardener,

From 10 to 50%, preferably from 15 to 50%, preferably from 20 to 50%, of polyamide / oligomer mixture in respective proportions by weight of 1/5 to 5/1;

on the total weight of the composition.

The composition of the invention may also comprise, for 100 parts of the curable resin, hardener, polyamide and oligomer assembly, up to 60 parts of an impact modifier comprising at least one copolymer chosen from SBM, BM and MBM block copolymers. wherein:

each block is connected to the other by means of a covalent bond or an intermediate molecule connected to one of the blocks by a covalent bond and to the other block by another covalent bond,

M is a homopolymeric PMMA or a copolymer comprising at least 50% by weight of methyl methacrylate, in particular M corresponds to methyl methacrylate,

B is incompatible with the thermoset resin and with the block M and its glass transition temperature Tg is lower than the temperature of use of the thermoset material obtained by the crosslinking of the composition of the invention, in particular B is butadiene

S is incompatible with the thermoset resin, the block B and the block M and its Tg or its melting temperature Tf is greater than the Tg of B, in particular S is styrene.

These impact modifiers have been described in application WO 0192415 A1.

Advantageously, the copolymer is the S-B-M block copolymer.

More preferably, the SBM block copolymer is styrene-butadiene-methacrylate The term "incompatible" means that B and S are not miscible with the thermoset resin, that M and B are not miscible with each other and that S, B and M are not miscible with each other either.

The amount added is advantageously up to 20 parts per 100 parts of composition, i.e., 100 parts of the set curable resin, hardener, polyamide and oligomer.

The compositions of the invention can be prepared by mixing the various constituents in any conventional mixing device while remaining in conditions such that they do not crosslink. The compositions are recovered in liquid, pasty or solid form depending on their nature. They are then put in molds, or spread on surfaces and then crosslinked. The thermoset material is thus obtained. Solid compositions (before crosslinking) can be milled for subsequent use as a powder.

Advantageously, the crosslinking is carried out by simple heating.

With regard to the epoxy resins, the materials of the invention with a low percentage of polyamide (≤20% by weight) can be prepared using a conventional stirred reactor. The thermosetting epoxy resin is introduced into the reactor and worn for a few minutes at a temperature sufficient to be fluid. The polyamide or copolymer and the oligomer are then added and kneaded at a temperature sufficient to be fluid until it is completely dissolved (below 120 ° C.). The mixing time depends on the nature of the polyamide or copolymer added. The hardener is then added and mixed for a further 5 minutes at a temperature sufficient to be fluid to obtain a homogeneous mixture. The epoxy-hardener reaction begins during this mixing and must therefore be set as short as possible. These mixtures are then poured and cooked in a mold.

For materials with a polyamide or copolymer content greater than 20% by weight, a premix of the thermosetting resin and the polyamide (or copolymer) is produced according to the following method: In a twin-screw extruder the epoxide in solid form, polyamide, the oligomer and the hardener at a temperature allowing the mixing of these different constituents without reaching the point of gelation. The resulting mixture is then milled and used in powder coating applications.

The conditions of cooking or hardening are the usual conditions.

It would not be outside the scope of the invention to add in the thermoset materials (before crosslinking) the usual additives / core shells, liquid elastomers and rubbers, high Tg thermoplastics, block copolymer type additives, or additives. allowing the modification of the fire or electrical properties or all types of mineral additives such as glass (in the form of fiber or ball) as well as all types of organic carbon or aramid type fibers.

The standards used in the description of the present invention are, for each parameter, indicated in the following Table 1:

Table 1

maximum stress JIS K71 13 527 maximum deformation JIS K71 13 527

[Examples]

Products used:

Epoxy resin :

Diglycidic Ether of Bisphenol A DGEBA (EEW = 190) from jeR 828.

Hardener:

Amine hardener which is diamino diphenyl sulphone (DDS).

Polyamide:

COPA: PA Pip.10 / 1 1 / Mass ratio pip.9 65/30/5

(Mn ~ 8000 g / mol, Tf ~ 106 ° C, Tg ~ 25 ° C)

Oliqomer:

CTBN 1300X8, liquid rubber

(Mn ~ 3500 g / mole, Tg ~ -52 ° C)

Procedure for the examples in Table 2:

- Add COPA and / or CTBN to DGEBA at 180 ° C;

mixing until complete dissolution of the COPA (for about 30 to 60 minutes) in the DGEBA matrix and degassing under vacuum;

- Add the DDS (Epoxy molar ratio: DDS = 1: 1), stir and homogenize, then degass under vacuum;

- Pour the mixture obtained in the previous step at 150 ° C into a mold to obtain plates: 4 mm thick to measure their mechanical properties / 6 mm thick for the measurement of K1 C;

- Hardening cycle: 2 hours at 1 10 ° C, ramp up to 200 ° C at 1 ° C / min, and 4 hours at 200 ° C, then cool.

Results of the examples in Table 2:

On this table which summarizes the tests carried out:

- The epoxy-based reference hardenable resin and DDS in the molar ratio 1/1, is denoted "RD" in Table 2. Comparative Examples Cp1 to Cp3: The epoxy / COPA mixture does not give an improvement of K1 C with respect to the curable resin of reference RD with regard to Cp1 and Cp2. On the other hand, the Tg decreases because of the miscibility between epoxy and COPA for the three examples Cp1 to Cp3. Addition of COPA, the epoxy matrix retains its rigidity and its impact resistance is improved.

Comparative Examples Cp4 and Cp5.1 and Cp5.2: The epoxy / CTBN mixture retains a high Tg and has an improved K1C, relative to the reference matrix RD and to the comparative examples Cp1 to Cp3. The addition of CTBN alone to the epoxy matrix lowers its modulus significantly (-35% approximately).

Examples according to the invention Ex1.1 and Ex1.2: The epoxy / COPA / CTBN mixture makes it possible to have a matrix with a moderate decrease in Tg, a significantly improved K1c, even more impressive in G1c. The matrix has a stiffness and impact resistance similar to that of the reference matrix.

Above all, a synergistic effect of the COPA / CTBN mixture in the epoxy matrix is observed on K1 C. While neither COPA alone nor CTBN alone can improve the K1 C of the epoxy matrix, the combined use COPA and CTBN improve K1 C and G1 C significantly (+ 60%).

Table 2

Claims

CLAIMS Composition comprising by weight, the total being 100%:

50 to 99% curable resin and hardener in a molar ratio in the range of 1/5 to 5/1, and

1 to 50% of a mixture:

polyamide which comprises at least one monomer resulting from the condensation of a diacid and a diamine of formula (1) below:

in which :

Composition according to any one of claims 1 or 2, wherein the diamine of formula 1 is chosen from piperazine and its derivatives, in particular aminoethylpiperazine.

Composition according to any one of the preceding claims, wherein the polyamide comprises from 10 to 100 mol%, preferably from 40 to 100 mol%, preferably from 50 to 100 mol%. at 100 mol%, preferably from 60 to 100 mol%, of at least one monomer chosen from: Pip.9, Pip.10, Pip.12, Pip.14, Pip.18, Pip.36, AEP.6 , AEP.9, AEP.10, AEP.12, AEP.14, AEP.18, AEP.36, and mixtures thereof, based on the total number of moles of polyamide of the composition, pip designating piperazine and AEP designating the aminoethylenepiperazine.

4. Composition according to any one of the preceding claims, characterized in that the polyamide further comprises at least one of the following monomers: 4.6, 4.T, 5.4, 5.9, 5.10, 5.12, 5.13, 5.14, 5.16, 5.18, 5.36, 6, 6.4, 6.9, 6.10, 6.12, 6.13, 6.14, 6.16, 6.18, 6.36, 6, 9, 10.4, 10.9, 10.10, 10.12, 10.13, 10.14, 10.16, 10.18, 10.36, 10.T, 1 1, 12, 12.4, 12.9, 12.10, 12.12, 12.13, 12.14, 12.16, 12.18, 12.36, 12.T, and mixtures thereof in alloy or copolyamide form.

5. Composition according to any one of the preceding claims, characterized in that the polyamide comprises at least one copolyamide chosen from: PA Pip.9 / Pip.12 / 1 1, PA 6 / Pip.12 / 12, PA 6.10 / Pip.10 / Pip.12, PA Pip.12 / 12, PA Pip.10 / 12, PA Pip.10 / 1 1 / Pip.9, and mixtures thereof.

6. Composition according to any one of claims 1 to 3 wherein the polyamide is a copolymer with polyamide blocks and polyether blocks (PEBA), the polyamide blocks resulting from the condensation of at least one diacid and at least one diamine of formula (1).

The composition of any one of the preceding claims wherein the curable resin is an epoxy resin.

The composition of any preceding claim wherein the hardener is a polyamine.

9. Composition according to any one of the preceding claims wherein the proportions by weight are:

on the total weight of the composition.

10. Composition according to any one of the preceding claims, also comprising, for 100 parts of the set of curable resin, hardener, polyamide and oligomer, up to 60 parts of an impact modifier comprising at least one copolymer chosen from block copolymers. SBM, BM and MBM in which:

M is a PMMA homopolymer or a copolymer comprising at least 50% by weight of methyl methacrylate, B is incompatible with the thermoset resin and with the block M and its glass transition temperature Tg is lower than the temperature of use of the thermoset material ,

S is incompatible with the thermoset resin, the block B and the block M and its Tg or its melting temperature Tf is greater than the Tg of B.

1 1. The composition of claim 10 wherein the copolymer is S-B-M block copolymers.

12. Composition according to claim 10 or 1 1, wherein S-B-M block copolymers is styrene-butadiene-methacrylate.

13. Thermoset material obtained by crosslinking the composition of any one of the preceding claims.

14. Use of a mixture of polyamide and oligomer in a thermoset matrix to improve its fracture toughness, as determined according to ASTMD5045,

the thermoset matrix comprising a curable resin and a hardener with a molar ratio in the range of 1/5 to

5/1

in which :

the oligomer being based on butadiene and acrylonitrile terminated either by carboxyl functions or by amine functions, such as the CTBN or ATBN reactive rubbers, said mixture representing from 1 to 90% by weight, relative to the total weight of the thermoset matrix, and the polyamide and the oligomer being in respective proportions by weight of 1/10 to 10/1, preferably of 1/5 to 5/1.