TWI424008B - 用於熔接二個聚醯胺部件之方法 - Google Patents

用於熔接二個聚醯胺部件之方法 Download PDF

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Publication number
TWI424008B
TWI424008B TW097109066A TW97109066A TWI424008B TW I424008 B TWI424008 B TW I424008B TW 097109066 A TW097109066 A TW 097109066A TW 97109066 A TW97109066 A TW 97109066A TW I424008 B TWI424008 B TW I424008B
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Taiwan
Prior art keywords
iron
containing additive
polyamine
composition
welding
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TW097109066A
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English (en)
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TW200902601A (en
Inventor
Wilhelmus Josephus Maria Sour
Antonius Maria Vet
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Dsm Ip Assets Bv
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Publication of TW200902601A publication Critical patent/TW200902601A/zh
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    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/139—Open-ended, self-supporting conduit, cylinder, or tube-type article
    • Y10T428/1393—Multilayer [continuous layer]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y10T428/31728—Next to second layer of polyamide

Description

用於熔接二個聚醯胺部件之方法
本發明係關於一種用於熔接二個聚醯胺部件之方法，二部件係由包含聚醯胺及任選地添加劑之聚醯胺組成物所製成。本發明進一步係關於經由該方法所獲得且包含二個聚醯胺部件熔接在一起之一種熔接塑膠本體。
此種方法及包含二個聚醯胺部件熔接在一起之此種塑膠本體由EP-1383825-A1為已知。於EP-1383825-A1中，敘述二個聚醯胺部件可藉振動熔接而熔接在一起。
技藝界已如由含聚醯胺之樹脂組成物製造模製物件。偶爾，對模製部件之幾何形狀要求超過將此種物件模製成為單塊的技術能力，或該模製只能使用相對昂貴且緩慢之脫核心模製方法來進行。結果，已經開發替代製造方法來允許製造相對複雜成形物件，該製法係經由首先模製該物件之各個部件，例如中空物件的兩個半殼，以及於第二步驟，將兩個半殼共同熔解來形成期望的物件。
但偶爾於製造有足夠強度可耐受此種熔接物件利用時所遭遇的力道時遭逢困難。包含二個聚醯胺部件共同熔接之熔接部件之塑膠本體常見的問題為熔接線之強度典型係遠低於二個聚醯胺部件本體之強度。當此種熔接的塑膠本體接受機械測試時，常於熔接線發生斷裂。特別，於熔接物件接受升高壓力之應用用途時熔接斷裂可能成問題。典型實例為汽車工業之空氣進氣歧管。例如當物件為內燃引 擎之空氣進氣歧管且引擎回火時可能出現此項問題。
解決該熔接強度問題之典型辦法為於將形成熔接線之周緣部增加該等部件之壁厚度。此種壁厚度之增加由於其它技術理由故並非經常性可能或期望。
有關熔接斷裂之又另一項問題為於多種情況下，添加化合物至熱塑性樹脂組成物，期望提高最終物件之熔解強度，可能導致模製物件之若干其它重要性質的降低。特別使用礦物填充組成物及玻璃纖維填充組成物，本體強度與熔接強度間之差異顯著，此外，當進一步提高填充劑數量或玻璃纖維數量時，熔接強度常受到不良影響。
EP-1383825-A1也處理有關包含二個熔接聚醯胺部件之塑膠本體強度不足的問題。為了提高具有二個熔接部件之塑膠本體之熔接強度，EP-1383825-A1提供一種方法，其中該二個聚醯胺部件係由不同的聚醯胺組成物所製成：第一部件係由一種聚醯胺組成物所製成，該組成物包含具有比第二部件之聚醯胺組成物中之聚醯胺更低的軟化點，及該第一部件之聚醯胺組成物進一步包含一種或多種黏度增加添加劑。
同樣問題之另一項解決之道係由WO98/11164所提供。WO98/11164說明一種熔接方法，其中，特定塑化化合物係含括於可製造該二個聚醯胺部件之聚醯胺樹脂組成物。於該二聚醯胺部件中之聚醯胺組分為相同。
使用EP-1383825-A1及WO98/11164之解決之道之問題為塑化劑及具有較低軟化點之聚醯胺的使用，降低熔接後 塑膠本體之挺度，而限制於升溫之用途。
由二個熔接聚醯胺部件所製成之塑膠本體之又一問題為熔接強度不僅比二個部件本體強度遠更低，同時也比二個部件本體之降級速度遠更快。
因此本發明之目的係提供一種熔接二個聚醯胺部件之方法，其獲得顯示改良之熔接強度效能及/或於升高溫度保有熔接強度效能之熔接後之塑膠本體。
使用根據本發明方法達成此項目的，其中二個聚醯胺部件中之至少一者係由包含含鐵添加劑之聚醯胺組成物所組成。
根據本發明之熔接方法中，組成該二個聚醯胺部件中之至少一者之聚醯胺組成物所包含之含鐵添加劑之效果為，熔接獲得熔接後之塑膠本體，比較由相對應之熔接方法其中該二個聚醯胺部件中之任一者之組成中皆未包含含鐵添加劑所得之相對應的熔接後之塑膠本體，前者顯示較高熔接強度及/或於升溫時之較高維持性。
於根據本發明之方法中，該二部件適合由相同聚醯胺組成物，以及由不同聚醯胺組成物所組成。不同聚醯胺組成物之差異在於一種組成物包含該含鐵添加劑及或該等組成物包含不同聚醯胺及/或不同額外添加劑。
於根據本發明之方法之較佳模式中，該二部件係由包含含鐵添加劑之聚醯胺組成物所組成。其優點為熔接後塑 膠本體之熔接強度進一步增高，且於升溫時之保持性較佳。
含鐵添加劑可包含單一金屬元素與可包含額外金屬元素。如此，添加劑可包含鐵含量組成金屬元素之總含量，或鐵含量組成總金屬含量之大部分。本發明之有利效果可能與添加劑之鐵含量有關，含鐵添加劑具有鐵含量相對於該含鐵添加劑之金屬含量總重至少為75 wt%，更佳至少為85 wt%，及又更佳至少為95 wt%。
適合，含鐵添加劑包含元素形式之鐵，亦即元素鐵及/或鐵氧化物及/或其鹽類。較佳含鐵添加劑相對於該含鐵添加劑之總非聚合物之重量比，包含至少60 wt%及更佳75 wt%元素鐵。
典型地，此種材料具有粒徑分布，大部分粒子具有粒徑至多約2毫米。通常，元素金屬具有重量平均粒徑(dm)至多為1毫米。
較佳，該含鐵添加劑所包含之元素鐵係精細分散於聚醯胺組成物。精細分散之元素鐵係由具有粒徑於寬廣範圍改變之粒子所組成。較佳，精細分散之元素鐵具有重量平均粒徑至多為500微米，更佳至多為300微米、200微米或甚至100微米，及又更佳至多為50微米。元素鐵具有極小粒徑，重量平均粒徑例如為10微米或5微米或甚至更小。元素鐵之重量平均粒徑較小之優點為熔接強度性質更進一步改良。
重量平均粒徑根據ASTM標準D1921-89方法A測定為Dm 。
根據本發明方法所使用之聚醯胺部件所包含之適當元素鐵例如為得自SMC金屬產品公司，俄亥俄州之SCM鐵粉 A-131。
適合包含鐵氧化物及/或其鹽之含鐵添加劑包含氧化鐵(II)[FeO]、氧化鐵(III)[Fe2 O3 ]及/或其組合[Fe3 O4 ]、鐵氧體、氧化磷鐵及/或其混合物。
氧化鐵及/或其鹽可包含具有於寬廣範圍改變之粒徑之粒子。較佳鐵氧化物及/或其鹽係由具有重量平均粒徑至多為1毫米，較佳至多為0.5毫米，更佳至多為0.1毫米，及又更佳至多為50微米之粒子所組成。
為了成本效益之理由，含鐵添加劑及特別為元素鐵較佳具有重量平均粒徑大於1微米，更佳大於2微米，及又更佳大於3微米。更細小之添加劑等級通常導致原料成本及混料成本的增高，而通常無法轉換成為效能的相對應增高。 此外，經過精細研磨之元素鐵也有爆炸風險。
含鐵添加劑之存在量可有寬廣變化。極小量確實對熔接強度性質有效，該效果隨著含鐵添加劑含量增高而增加。於高含量時此種效果變均平。較佳相對於聚醯胺組成物之總重，含鐵添加劑之存在量為0.10-10 wt%，更佳為0.05-4 wt%，及又更佳為0.1-2wt%。較高量之優點為熔解線性質進一步增高。
含有該含鐵添加劑之聚醯胺組成物中之該聚醯胺聚合物可為任一種適合用於由其中製造聚醯胺部件及/或製造熔接的塑膠本體之任一種聚醯胺聚合物。
適合該聚醯胺聚合物為熱塑性聚醯胺、非晶形或半晶形聚醯胺及脂肪族或半芳香族聚醯胺。
適當脂肪族聚醯胺例如為PA-6、PA-11、PA-12、PA-4,6、PA-4,8、PA-4,10、PA-4,12、PA-6,6、PA-6,9、PA-6,10、PA-6,12、PA-10,10、PA-12,12、PA-6/6,6-共聚醯胺、PA-6/12-共聚醯胺、PA-6/11-共聚醯胺、PA-6,6/11-共聚醯胺、PA-6,6/12-共聚醯胺、PA-6,6/10-共聚醯胺、PA-6,6/6,10-共聚醯胺、PA-4,6/6-共聚醯胺、PA-6/6,6/6,10-三聚醯胺、及由1,4-環己二羧酸及2,2,4-及2,4,4-三甲基六亞甲基二胺所得之共聚醯胺，及前述聚醯胺之共聚醯胺。
適當半芳香族聚醯胺例如為PA-6,I、PA-6,I/6,6-共聚醯胺、PA-6,T、PA-6,T/6-共聚醯胺、PA-6,T/6,6-共聚醯胺、PA-6,I/6,T-共聚醯胺、PA-6,6/6,T/6,I-共聚醯胺、PA-6,T/2-MPMD,T-共聚醯胺(2-MPMD=2-甲基五亞甲基二胺)、PA-9,T、PA-9T/2-MOMD,T(2-MOMD=2-甲基-1,8-八亞甲基二胺)、由對苯二甲酸、2,2,4-及2,4,4-三甲基六亞甲基二胺所得之共聚醯胺、由間苯二甲酸、月桂精內醯胺及3,5-二甲基-4,4-二胺基-二環己基甲烷所得之共聚醯胺、由間苯二甲酸、壬二酸及/或癸二酸與4,4-二胺基二環己基甲烷所得之共聚醯胺、由己內醯胺、間苯二甲酸及/或對苯二甲酸與4,4-二胺基環己基甲烷所得之共聚醯胺、由己內醯胺、間苯二甲酸及/或對苯二甲酸與異佛爾酮二胺所得之共聚醯胺、由間苯二甲酸及/或對苯二甲酸及/或其它芳香族或脂肪族二羧酸，任選地，經烷基取代之六亞甲基二胺及經烷基取代之4,4-二胺基二環己基胺所得之共聚物、及前述聚醯胺之共聚醯胺。
較佳聚醯胺係選自於由PA-6、PA-6,6、PA-6,10'、PA-4,6、PA-11、PA-12、PA-12,12、PA-6,I、PA-6,T、PA-6,I/6,T-共聚醯胺、PA-6,T/6,6-共聚醯胺、PA-6,T/6-共聚醯胺、PA-6/6,6-共聚醯胺、PA-6,6/6,T/6,I-共聚醯胺、PA-6,T/2-MPMD,T-共聚醯胺、PA-9,T、PA-9T/2-MOMD,T-共聚醯胺、PA-4,6/6-共聚醯胺及前述聚醯胺之混合物及共聚醯胺。更佳，選用PA-6,I、PA-6,T、PA-6,I/6,T-共聚醯胺、PA-6,6、PA-6,6/6T、PA-6,6/6,T/6,I-共聚醯胺、PA-6,T/2-MPMD,T-共聚醯胺、PA-9,T、PA-9T/2-MOMD、T-共聚醯胺或PA-4,6、或其混合物或共聚物作為聚醯胺。
較佳聚醯胺聚合物為具有玻璃轉換溫度(Tg)之非晶形聚醯胺或具有熔點(Tm)之半晶形聚醯胺，其中該溫度為非晶形聚醯胺之Tg或半晶形聚醯胺之Tm至少為200℃，更佳至少為200℃、250℃、270℃、280℃或甚至至少為290℃。
熔點一詞於此處須了解為藉DSC以10℃/分鐘之加熱速率測量且測定為有最高熔解焓之溫度之熔點。
玻璃轉換溫度一詞於此處須了解為根據ASTM E 1356-91藉DSC以20℃/分鐘之加熱速率測定，且以親代熱曲線之第一導數峰值(就時間而言)與親代熱曲線之反曲點相對應之溫度。
根據涉及聚醯胺部件之狀態，使用熔接方法，以PA6及低玻璃含量獲得最佳熔接結果。本發明之效果為使用其它有較高Tg或Tm之聚醯胺可獲得較佳結果，及使用較高玻璃含量也可獲得較佳結果。
其效果為具有較高熱扭變溫度(HDT)之產物可獲得較佳熔接結果，因而延伸熔接塑膠本體可使用之溫度範圍。
較佳，根據ISO 75/A測量，聚合物組成物具有HDT至少為200℃、230℃、250℃、260℃、或甚至至少為270℃。
較佳聚醯胺聚合物包含PA-6,6、PA-4,6及/或半晶形半芳香族聚醯胺對苯二甲酸酯、及/或其任一種共聚物。
適合聚醯胺組成物包含含第一聚醯胺及第二聚醯胺之至少兩種聚醯胺之摻和物。於根據本發明方法之較佳實施例中，聚醯胺聚合物為具有熔點至少260℃之半晶形聚醯胺與具有熔點低於260℃之第二聚醯胺之摻和物，或此處該第二聚醯胺為具有玻璃轉換溫度低於260℃之非晶形聚醯胺。較佳第一聚醯胺為PA-6,6、PA-4,6及/或半晶形半芳香族聚醯胺對苯二甲酸酯、及/或其任一種共聚物；而第二聚醯胺為PA-6或其共聚醯胺。
也適合於根據本發明方法之二部件間藉此所得之熔解塑膠本體係由不同聚醯胺組成物所組成。此等不同聚醯胺組成物之差異在於兩種組成物各自包含之聚醯胺聚合物不同。
適合，一個部件(部件L)之聚醯胺聚合物具有比另一個部件(部件H)之聚醯胺更低的軟化溫度，其中該部件L之聚醯胺組成物包含高分子量聚醯胺及/或提高黏度之添加劑。
聚醯胺組成物除了該聚醯胺聚合物及含鐵添加劑之外可包含一種或多種添加劑。
此等添加劑適合包括熟諳技藝人士已知習常用於熔接方法步驟之聚醯胺組成物中之填充劑、加強纖維及其它添 加劑，但限制條件為其大致上不會造成本發明之不利影響。聚醯胺組成物可包含之其它適當添加劑例如為與聚醯胺不同之熱塑性聚合物、耐衝擊改性劑(諸如橡膠及彈性體)、增容劑、顏料、阻燃劑、安定劑(例如紫外光吸收劑、抗氧化劑、及熱安定劑)、加工劑(離型劑、孕核劑)、及無機鹽類、酸化組分及其混合物。適當無機鹽類之實例包括鹼金屬、鹼土金屬、及過渡金屬、鹵化物、硫酸鹽、硝酸鹽、碳酸鹽、羧酸鹽、亞硫酸鹽及磷酸鹽，諸如氯化鈉、溴化鉀、碘化鉀、碳酸鈣、硫酸鎂、硝酸銅、碘化銅、乙酸銅及其混合物。適當酸化組分例如為磷緩衝劑諸如焦磷酸鹽，其適當實例為焦磷酸鈉(Na2 H2 PO7 )。
可用作為耐衝擊改性劑之適當橡膠例如為SBS橡膠及EPDM橡膠。
除了聚醯胺聚合物外，可用於聚醯胺組成物之熱塑性聚合物可為任一型適合用於涉及熔接方法步驟之用途之模製聚合物中之任一型熱塑性聚合物。熱塑性聚合物例如為非晶形聚合物或半晶形聚合物。適當非晶形聚合物例如為聚醯胺類(PI)、聚醚碸類(PES)、聚醚醯亞胺類(PEI)、聚碸類(PSU)、及聚芳酸酯類(PAR)、非晶形聚酯類(PES)。適當半晶形聚合物例如為聚醚醚酮類(PEEK)、聚伸苯基硫化物類(PPS)及半芳香族熱塑性聚酯類。熱塑性聚合物也可為聚烯烴諸如聚乙烯(PE)、聚丙烯(PP)、及PE/PP共聚物。熱塑性聚合物也包含不同熱塑性聚合物之摻和物。
若使用時，相對於聚醯胺聚合物之重量，熱塑性聚合 物之存在量為0.1-20重量%，更佳0.5-10重量%，及最佳1-5重量%。
增容劑較佳係組合熱塑性聚合物及與該熱塑性聚合物之可相容性低之耐衝擊改性劑組合使用。
適當顏料包括黑顏料諸如碳黑及尼格辛黑(nigrosine)及白顏料諸如TiO2 及ZnS。
適當熱安定劑例如為酚系熱安定劑(例如伊佳諾(Irganox)1098)、磷酸酯(例如伊佳佛(Irgafos)168)、芳香族胺類及金屬鹽類。適當金屬鹽之實例例如為二硫基胺基甲酸鎳(例如哈斯塔文(Hostavin)VPNICS1)、二硫基胺基甲酸鋅(例如哈斯塔諾(hostanox)VPZnCS1)及銅鹽(例如CuI/KI)。
特別聚醯胺組成物較佳包含填充劑及/或加強纖維。
此處須了解填充劑為顆粒狀材料。填充劑之粒子有寬廣多種結構，例如片狀、板狀、米粒狀、六角形、或球狀形狀。填充劑可為聚醯胺模製化合物製造技藝界之熟諳技藝人士已知之任一種填充劑。適合包含於根據本發明之聚醯胺組成物之填充劑具有縱橫比L/D<5。也適合填充劑為無機填充劑例如包括玻璃珠；有機填充劑例如硫酸鋇及矽酸鋁、及礦物填充劑，諸如滑石、碳酸鈣、高嶺土、矽灰石、雲母、黏土及煆燒黏土。填充劑以需要可經表面處理來獲得與熱塑性聚醯胺之更佳可相容性。
根據本發明方法所使用之聚醯胺部件及藉該方法所得之熔接塑膠本體中之至少一個部件可包含纖維狀加強劑， 且可為適合用於經纖維加強之熱塑性熔接塑膠本體之任一型纖維狀加強劑。纖維狀加強劑於此處考慮為具有長度、寬度及厚度之材料，其中該平均長度係顯著大於其寬度及厚度。大致上此種材料具有以長度(L)與長度及寬度中之最大者(D)間之平均比定義之縱橫比L/D至少為5。較佳纖維狀加強劑之縱橫比至少為10，更佳至少為20，又更佳至少為50。
適當纖維狀加強劑例如為非金屬纖維狀加強劑諸如玻璃纖維、碳纖維或石墨纖維、芳醯胺樹脂纖維、陶瓷纖維、礦物纖維諸如矽灰石及晶鬚；由於根據本發明組成物所涵蓋之應用領域，金屬纖維諸如銅、鐵及鋁纖維用於根據本發明之方法及組成物並不佳。
由根據本發明方法所使用之聚醯胺部件所包含之填充劑及纖維狀加強劑之含量可於寬廣範圍改變。通常相對於100 pbw聚醯胺聚合物，數量係於0至300份重量比(pbw)之範圍。較佳相對於100 pbw聚醯胺聚合物，用量為5-235 pbw，更佳為10-150 pbw，及又更佳為25-100 pbw。
適合聚醯胺組成物包含選自於由安定劑包含銅鹽、填充劑(例如礦物填充劑)；纖維狀加強劑、鹼性鹵化物(諸如氯化鈉)及焦磷酸鹽(諸如焦磷酸鈉或Na2 H2 PO7 )所組成之組群中之至少一種添加劑。其各自之優點為可進一步提升熔接強度。
較佳該聚醯胺組成物包含銅鹽如CuI及/或鹼性鹵化物，諸如KI及/或NaCI、及/或焦磷酸鈉之組合物。
銅鹽、鹼性鹵化物及/或焦磷酸鈉之組合物相對於聚醯 胺組成物之總重，較佳係以總量0.001-10 wt.%存在，更佳為0.01-5 wt.%，又更佳為0.01-3 wt.%。
較佳相對於聚醯胺組成物之總重，填充劑及/或纖維狀加強劑係以總量1-70 wt.%，更佳為10-50 wt.%存在。
於本發明之較佳實施例中，至少一個部件係由一種聚醯胺組成物所組成，包含。30-95 wt.% pbw聚醯胺聚合物。0.01-10 wt%含鐵添加劑。0-70 wt%填充劑及/或纖維狀加強劑，。0.01-5 wt.%選自於銅鹽、鹼性鹵化物及焦磷酸鹽中之至少一種添加劑，及。0-20 wt.%額外添加劑。
於一更佳實施例中，該聚醯胺組成物包含。30-90 wt.% pbw聚醯胺聚合物。0.05-5 wt%含鐵添加劑。5-70 wt%填充劑及/或纖維狀加強劑，。0.1-3 wt.%選自於銅鹽、鹼性鹵化物及焦磷酸鹽中之至少一種添加劑，及。0-10 wt.%額外添加劑。
此處重量百分比(wt.%)係相對於聚醯胺組成物之總重計算。
根據本發明方法所使用之聚醯胺部件可藉適合用於製造聚醯胺部件之任一種方法製造。較佳聚醯胺部件係藉射出模製法或擠塑法製造。
根據本發明之方法中之熔接步驟涉及適合用於熔接聚醯胺部件之任一種熔接技術。適當熔接技術例如為接觸熔接、電磁熔接、熱板熔接、高頻熔接、超音波熔接、振動熔接、或摩擦熔接及雷射熔接。但由於含鐵添加劑之典型不透明本質故雷射熔接通常並不佳。
較佳熔接技術係選自於由接觸熔接、熱板熔接、高頻熔接、超音波熔接、振動熔接、或摩擦熔接所組成之組群。
較佳，熔接係藉振動熔接或熱板熔接進行，更佳為振動熔接。
藉根據本發明方法且由根據本發明之熔接塑膠部件所包含之熔接接頭可為任一種經由熔接至塑膠部件所得之任何熔接接頭。適當熔接接頭為對接頭、角隅接頭、T字形接頭、榫接頭或緣接頭。
本發明亦係關於包含將兩個聚醯胺部件熔接在一起之熔接塑膠本體。於根據本發明之熔接塑膠本體中，兩個聚醯胺部件中之至少一者係由包含含鐵添加劑之聚醯胺組成物所組成。
於包含由該聚醯胺組成物所組成之至少一個聚醯胺部件之熔接後的塑膠本體中包含含鐵添加劑之效果如前文說明為熔接強度效能提升。
本發明特別係關於藉根據本發明方法及前述任何實施例或較佳實施例所得之熔接後之塑膠本體。較佳，於根據本發明之熔接後之塑膠本體之至少一個部件中，包含該含鐵添加劑之聚醯胺組成物具有一種組成物且包含前文對根據本 發明之熔接方法所述之任一種較佳實施例之額外組分。
熔接後之塑膠本體可為任一種根據本發明方法所能獲得之塑膠本體。根據本發明之方法適合用於製造浪形管、風箱、容器、燃料進入系統、空氣進氣歧管、空氣導管。
本發明進一步係關於使用根據本發明之方法所製造之浪形管、風箱、中間冷卻器端帽、容器、燃料進入系統、空氣進氣歧管、空氣導管。
參照下列實例及比較實驗進一步說明本發明。
使用的材料
PA-6聚醯胺6，型號K122、黏度值115毫升/克(根據ISO 307測定)(得自荷蘭DSM)
PA-4,6聚醯胺-4,6，型號KS 200、黏度值160毫升/克(根據ISO 307測定)(得自荷蘭DSM)
GF-I玻璃纖維加強劑用於聚醯胺-6之標準型玻璃纖維
GF-II玻璃纖維加強劑用於聚醯胺-46之標準型玻璃纖維
AADS輔助添加劑：標準添加劑之組合物包含潤滑劑附屬離型劑、CuI/KI安定劑、顏料濃縮物、載劑聚合物及增容劑
ICA含鐵添加劑：於PE之母批料含有20重量%元素鐵顆粒平均粒徑30微米。
聚醯胺組成物之製備 比較實驗例A:PA-6-GF
30 wt%經過玻璃纖維加強之PA-6-1-GF係於雙螺桿擠塑機型號ZSK 30於料筒溫度260℃，螺桿速度250 rpm，由 PA-6與GF混料製成。
比較實驗例B:PA-4,6-GF
30 wt%經玻璃纖維加強之PA-4,6-GF係於ZSK 25擠塑機於料筒溫度300℃，螺桿速度275 rpm(通量20千克/小時)由PA-4,6與GF-II及規則加工助劑及安定劑混料製備。
實例I:PA-6/46-GF-ICA-1
經以含鐵添加劑改性之35 wt%經玻璃纖維加強之聚醯胺-6/46組成物之製法，係經由於比較實驗例B之相同條件下，於ZSK25雙螺桿擠塑機上混料聚醯胺-6及聚醯胺-4,6(重量比25/75)、玻璃纖維GF-II、規則加工助劑及安定劑及2.5重量%元素鐵母批料製成。
實例II:PA-6/46-GF-ICA-2
經以含鐵添加劑改性之40 wt%經玻璃纖維加強之聚醯胺-6/46組成物之製法，係經由於比較實驗例B之相同條件下，於ZSK25雙螺桿擠塑機上混料聚醯胺-6及聚醯胺-4,6(重量比50/50)、玻璃纖維GF-II、規則加工助劑及安定劑及2.5重量%元素鐵母批料製成。
射出模製
對全部測試材料根據下述條件射出模製尺寸120毫米×120毫米×4毫米之板
聚醯胺-6材料之射出模製
於KM 120射出模製機上，使用料筒溫度設定值230-260℃及模具溫度80℃，進行比較實驗例A之聚醯胺-6材料之射出模製。
聚醯胺-4,6材料之射出模製
於KM 120射出模製機上，使用料筒溫度設定值300-310℃及模具溫度120℃，進行實例I-II及比較實驗例B之聚醯胺-4,6及聚醯胺-6/4,6材料之射出模製。
振動熔接
熔接測試係於比洛馬克(Bielomatik)(紐芬(Neuffen)，德國)振動熔接機型號K3210進行。熔接參數如下：頻率：240 Hz；振幅：0.9毫米；熔接壓力：2 Mpa；熔接時間：4秒；維持時間：7秒。該方法經控制時間而獲得1.8毫米之估計熔接深度。對各種材料執行4次熔接。
用於熔接測試目的，射出模製部件順著120毫米寬度切割對半。對接熔接試樣於工具內定向，120毫米×4毫米模製面與切線相對之120毫米×4毫米模製面變成熔接區。模製面上出現之熔接充分表示工業熔接程序。振動係平行於120毫米板寬度。
拉力測試
對接熔接之試樣切成寬10毫米之拉力試驗件，載荷於吉威克(Zwick)測試機上直到於10毫米/分鐘之十字頭速度斷裂為止。將斷裂時之力藉熔接面積4毫米×10毫米規度化獲得抗拉強度。應變係使用延長計測量，確定為斷裂點巨觀應變；多種情況下之實際應變遠更高。所列舉之數值為四個試驗件之平均值。
實例及比較實驗例
根據前述方法之振動熔接對表I列舉之材料組合物進 行根據前述方法之振動熔接。根據前述方法對此等熔接後之材料進行拉力測試。試驗結果報告於表I。
結果顯示根據本發明之組成物(實例I-II)之熔接強度可媲美或甚至優於聚醯胺-6之熔接強度，儘管實例I-II中之大部分聚醯胺聚合物係由聚醯胺-4,6所組成，其本身所得的結果比聚醯胺-6差(參考比較實驗例A及B)，且實例I-II含有較高重量百分比之玻璃纖維，通常對熔接線性質造成不良影響。

Claims (18)

  1. 一種用於熔接二個聚醯胺部件之方法，包含一方法步驟，其中製造該二個聚醯胺部件間之一個熔接接頭，以及其中兩個聚醯胺部件係由包含聚醯胺聚合物以及視需要可包含添加劑之一種聚醯胺組成物所組成，其特徵在於該二個聚醯胺部件中之至少一者係由包含含鐵添加劑之聚醯胺組成物所組成，且該含鐵添加劑之量足以提供一強固熔接接頭及/或改善該熔接接頭於升高溫度時的維持性。
  2. 如申請專利範圍第1項之方法，其中該二個部件各自係由包含含鐵添加劑之聚醯胺組成物所組成。
  3. 如申請專利範圍第1或2項之方法，其中該含鐵添加劑包含元素鐵及/或鐵氧化物及/或其鹽。
  4. 如申請專利範圍第3項之方法，其中該含鐵添加劑包含元素鐵。
  5. 如申請專利範圍第3項之方法，其中該含鐵添加劑具有鐵含量相對於該含鐵添加劑中之總金屬含量為至少75wt.%。
  6. 如申請專利範圍第4項之方法，其中該含鐵添加劑包含具有重量平均粒徑至多為450微米之細小分散之元素鐵。
  7. 如申請專利範圍第4項之方法，其中該含鐵添加劑包含具有重量平均粒徑大於1微米之細小分散之元素鐵。
  8. 如申請專利範圍第3項之方法，其中該含鐵添加劑包含氧化鐵(II)、氧化鐵(III)及/或其組合物、鐵氧體(ferrite)、 及/或氧化磷鐵。
  9. 如申請專利範圍第3項之方法，其中該含鐵添加劑包含具有重量平均粒徑至多為1毫米之鐵氧化物或其鹽。
  10. 如申請專利範圍第1-2項中任一項之方法，其中該含鐵添加劑之存在量相對於該聚醯胺組成物之總重為0.01-10重量%。
  11. 如申請專利範圍第1-2項中任一項之方法，其中該包含該含鐵添加劑之聚醯胺組成物包含選自於由填充劑、纖維、安定劑、加工助劑及輔助添加劑所組成之群組中之一種添加劑。
  12. 如申請專利範圍第1-2項中任一項之方法，其中該包含該含鐵添加劑之聚醯胺組成物包含銅鹽、及/或鹼性鹵化物及/或焦磷酸鹽。
  13. 如申請專利範圍第1-2項中任一項之方法，其中該二個聚醯胺部件之聚醯胺組成物包含無機填充劑及/或纖維加強劑。
  14. 如申請專利範圍第1-2項中任一項之方法，其中該熔接係藉振動熔接或熱板熔接進行。
  15. 如申請專利範圍第13項之方法，其中該熔接係藉振動熔接進行。
  16. 一種包含二個聚醯胺部件熔接在一起之經熔接之塑膠本體，該二個聚醯胺部件係由包含聚醯胺聚合物以及視需要可包含一或多種添加劑之一種聚醯胺組成物所組成，其特徵在於該二個聚醯胺部件中之至少一者係由包 含含鐵添加劑之聚醯胺組成物所組成。
  17. 如申請專利範圍第16項之經熔接之塑膠本體，其中該經熔接之塑膠本體為經由如申請專利範圍第1-15項中任一項之方法所得之經熔接之塑膠本體。
  18. 一種產物，其係選自於由如申請專利範圍第1-11項中任一項之方法所製造之浪形管、風箱、中間冷卻器端帽、容器、燃料進入系統、空氣進氣歧管、空氣導管所組成之組群。
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