US20120108129A1 - Polyamide composite structures and processes for their preparation - Google Patents

Polyamide composite structures and processes for their preparation Download PDF

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Publication number
US20120108129A1
US20120108129A1 US13/282,518 US201113282518A US2012108129A1 US 20120108129 A1 US20120108129 A1 US 20120108129A1 US 201113282518 A US201113282518 A US 201113282518A US 2012108129 A1 US2012108129 A1 US 2012108129A1
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US
United States
Prior art keywords
resin composition
composite structure
fibrous material
matrix resin
polyamide
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/282,518
Other languages
English (en)
Inventor
Andri E. Elia
Olaf Norbert Kirchner
David V. Mesaros
Martyn Douglas Wakeman
Shengmei Yuan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to US13/282,518 priority Critical patent/US20120108129A1/en
Assigned to E. I. DU PONT DE NEMOURS AND COMPANY reassignment E. I. DU PONT DE NEMOURS AND COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIRCHNER, OLAF NORBERT, ELIA, ANDRI E., MESAROS, DAVID V., WAKEMAN, MARTYN DOUGLAS, YUAN, SHENGMEI
Publication of US20120108129A1 publication Critical patent/US20120108129A1/en
Abandoned legal-status Critical Current

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Classifications

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    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric
    • Y10T442/2992—Coated or impregnated glass fiber fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet

Definitions

  • the present invention relates to the field of composite structures and processes for their preparation, particularly it relates to the field of polyamide composite structures.
  • composite materials are desired due to a unique combination of lightweight, high strength and temperature resistance.
  • thermosetting resins or thermoplastic resins as the polymer matrix.
  • Thermoplastic-based composite structures present several advantages over thermoset-based composite structures such as, for example, the fact that they can be post-formed or reprocessed by the application of heat and pressure, that a reduced time is needed to make the composite structures because no curing step is required, and their increased potential for recycling. Indeed, the time consuming chemical reaction of cross-linking for thermosetting resins (curing) is not required during the processing of thermoplastics.
  • thermoplastic resins polyamides are particularly well suited for manufacturing composite structures.
  • Thermoplastic polyamide compositions are desirable for use in a wide range of applications including parts used in automobiles, electrical/electronic parts, household appliances and furniture because of their good mechanical properties, heat resistance, impact resistance and chemical resistance and because they may be conveniently and flexibly molded into a variety of articles of varying degrees of complexity and intricacy.
  • thermoplastic sheet material useful in forming composites.
  • the disclosed thermoplastic sheet material is made of polyamide 6 and a dibasic carboxylic acid or anhydride or esters thereof and at least one reinforcing mat of long glass fibers encased within said layer.
  • Overmolding involves shaping, e.g. by injection molding, a second polymer part directly onto at least a portion of one or more surfaces of the composite structure, to form a two-part composite structure, wherein the two parts are adhered one to the other at least at one interface.
  • the polymer compositions used to impregnate the fibrous material (i.e. the matrix polymer composition) and the polymer compositions used to overmold the impregnated fibrous material (i.e. the overmolding polymer composition) are desired to have good adhesion one to the other, extremely good dimensional stability and retain their mechanical properties under adverse conditions, including thermal cycling, so that the composite structure is protected under operating conditions and thus has an increased lifetime.
  • thermoplastic polyamide resin compositions that are used to impregnate one or more fibrous layers and to overmold the one or more impregnated fibrous layers may require excessive heating during stamping, forming, or shaping, which may render their surfaces poor in appearance and in functionality, and/or may show poor adhesion between the overmolded polymer and the surface of the component comprising the fibrous material, i.e. the composite structure.
  • the poor adhesion may result in the formation of cracks at the interface of the overmolded composite structures leading to reduced mechanical properties, premature aging and problems related to delamination and deterioration of the article upon use and time.
  • thermoplastic polyamide composite structure that is easier to process in forming, shaping, or stamping, that exhibits good mechanical properties, especially flexural strength and having at least a portion of its surface allowing a good adhesion between its surface and an overmolding resin comprising a polyamide resin.
  • Described herein is a composite structure having a surface, which surface has at least a portion made of a surface resin composition, and comprising a fibrous material selected from the group consisting of non-woven structures, textiles, fibrous battings and combinations thereof, said fibrous material being impregnated with a matrix resin composition, wherein the surface resin composition is selected from polyamide compositions comprising a blend of two or more fully aliphatic polyamides having a melting point of at least 250° C. and wherein the matrix resin composition is selected from polyamide compositions comprising a one or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the surface resin composition is selected from polyamide compositions comprising a blend of poly(tetramethylene hexanediamide) (PA46) with one or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the surface resin composition is selected from polyamide compositions comprising a blend of poly(tetramethylene hexanediamide) (PA46) with poly(hexamethylene hexanediamide) (PA66).
  • the surface resin composition and the matrix resin composition are selected from polyamide compositions comprising a blend of poly(tetramethylene hexanediamide) (PA46) with poly(hexamethylene hexanediamide) (PA66).
  • the process for making the composite structure described above comprises a step of i) impregnating with the matrix resin composition the fibrous material, wherein at least a portion of the surface of the composite structure is made of the surface resin composition.
  • the composite structure according to the present invention has improved impact resistance and flexural strength and allows a good adhesion when a part made of an overmolding resin composition comprising a thermoplastic polyamide is adhered onto at least a portion of the surface of the composite structure.
  • a good impact resistance and flexural strength of the composite structure and a good adhesion between the composite structure and the overmolding resin leads to structures exhibiting good resistance to deterioration and resistance to delamination of the structure with use and time.
  • melting point in reference to a polyamide refers to the melting point of the pure resin as determined with differential scanning calorimetry (DSC) at a scan rate of 10° C./min in the first heating scan, wherein the melting point is taken at the maximum of the endothermic peak.
  • DSC differential scanning calorimetry
  • more than one heating scans may be performed on a single specimen, and the second and/or later scans may show a different melting behavior from the first scan. This different melting behavior may be observed as a shift in temperature of the maximum of the endothermic peak and/or as a broadening of the melting peak with possibly more than one peaks, which may be an effect of possible transamidation in the case of more than one polyamides.
  • a scan rate is an increase of temperature per unit time. Sufficient energy must be supplied to maintain a constant scan rate of 10° C./min until a temperature of at least 30° C. and preferably at least 50° C. above the melting point is reached.
  • the present invention comprises a fibrous material that is impregnated with a matrix resin composition. At least a portion of the surface of the composite structure is made of a surface resin composition.
  • the matrix resin composition and the surface resin composition may be identical or may be different.
  • a fibrous material being impregnated with a matrix resin composition means that the matrix resin composition encapsulates and embeds the fibrous material so as to form an interpenetrating network of fibrous material substantially surrounded by the matrix resin composition.
  • the term “fiber” refers to a macroscopically homogeneous body having a high ratio of length to width across its cross-sectional area perpendicular to its length.
  • the fiber cross section can be any shape, but is typically round.
  • the fibrous material may be in any suitable form known to those skilled in the art and is preferably selected from non-woven structures, textiles, fibrous battings and combinations thereof. Non-woven structures can be selected from random fiber orientation and aligned fibrous structures.
  • random fiber orientation examples include without limitation chopped and continuous material which can be in the form of a mat, a needled mat or a felt.
  • aligned fibrous structures include without limitation unidirectional fiber strands, bidirectional strands, multidirectional strands, multi-axial textiles. Textiles can be selected from woven forms, knits, braids and combinations thereof.
  • the fibrous material can be continuous or discontinuous in form.
  • the first component described herein may comprise one or more fibrous materials.
  • An example of a combination of different fibrous materials is a combination comprising a non-woven structure such as for example a planar random mat which is placed as a central layer and one or more woven continuous fibrous materials that are placed as outside layers. Such a combination allows an improvement of the processing and thereof of the homogeneity of the first component thus leading to improved mechanical properties.
  • the fibrous material may be made of any suitable material or a mixture of materials provided that the material or the mixture of materials withstand the processing conditions used during impregnation by the matrix resin composition and the surface resin composition.
  • the fibrous material comprises glass fibers, carbon fibers, aramid fibers, graphite fibers, metal fibers, ceramic fibers, natural fibers or mixtures thereof; more preferably, the fibrous material comprises glass fibers, carbon fibers, aramid fibers, natural fibers or mixtures thereof; and still more preferably, the fibrous material comprises glass fibers, carbon fibers and aramid fibers or mixture mixtures thereof.
  • natural fiber it is meant any of material of plant origin or of animal origin.
  • the natural fibers are preferably derived from vegetable sources such as for example from seed hair (e.g. cotton), stem plants (e.g. hemp, flax, bamboo; both bast and core fibers), leaf plants (e.g.
  • sisal and abaca examples include agricultural fibers (e.g., cereal straw, corn cobs, rice hulls and coconut hair) or lignocellulosic fiber (e.g. wood, wood fibers, wood flour, paper and wood-related materials).
  • agricultural fibers e.g., cereal straw, corn cobs, rice hulls and coconut hair
  • lignocellulosic fiber e.g. wood, wood fibers, wood flour, paper and wood-related materials.
  • fibrous materials made of different fibers can be used such as for example a composite structure comprising one or more central layers made of glass fibers or natural fibers and one or more surface layers made of carbon fibers or glass fibers.
  • the fibrous material is selected from woven structures, non-woven structures and combinations thereof, wherein said structures are made of glass fibers and wherein the glass fibers are E-glass filaments with a diameter between 8 and 30 microns and preferably with a diameter between 10 to 24 microns.
  • the fibrous material may further contain a thermoplastic material and the materials described above, for example the fibrous material may be in the form of commingled or co-woven yarns or a fibrous material impregnated with a powder made of a thermoplastic material that is suited to subsequent processing into woven or non-woven forms, or a mixture for use as a uni-directional material or a fibrous material impregnated with oligomers that will polymerize in situ during impregnation.
  • a thermoplastic material and the materials described above, for example the fibrous material may be in the form of commingled or co-woven yarns or a fibrous material impregnated with a powder made of a thermoplastic material that is suited to subsequent processing into woven or non-woven forms, or a mixture for use as a uni-directional material or a fibrous material impregnated with oligomers that will polymerize in situ during impregnation.
  • the ratio between the fibrous material and the polymer materials in the first component is at least 30 volume percent fibrous material and more preferably between 40 and 60 volume percent fibrous material, the percentage being a volume-percentage based on the total volume of the first component.
  • the surface resin composition is selected from polyamide compositions comprising a blend of two or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the surface resin composition is selected from polyamide compositions comprising a blend of poly(tetramethylene hexanediamide) (PA46) with one or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the surface resin composition is selected from polyamide compositions comprising a blend of poly(tetramethylene hexanediamide) (PA46) with poly(hexamethylene hexanediamide) (PA66).
  • the matrix resin composition is selected from polyamide compositions comprising one or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the matrix resin composition is selected from polyamide compositions comprising a blend of two or more fully aliphatic polyamides having a melting point of at least 250° C.
  • the matrix resin composition is selected from polyamide compositions comprising a poly(tetramethylene hexanediamide) (PA46) or poly(hexamethylene hexanediamide) (PA66) and mixtures or blends thereof.
  • PA46 poly(tetramethylene hexanediamide)
  • PA66 poly(hexamethylene hexanediamide)
  • the matrix resin composition and the surface resin composition may be identical or different.
  • the matrix resin composition and the surface resin composition are different, it means that their respective blend of polyamides comprises at least one different polyamide, or that their blend of polyamides are the same polyamides but made of different ratios.
  • the surface resin composition and the matrix resin composition comprise a blend of two or more or more fully aliphatic polyamides having a melting point of at least 250° C. in a weight ratio from about 1:99 to about 95:5, more preferably from about 15:85 to about 85:15. Still more preferably surface resin composition and the matrix resin composition comprises a blend of two or more or more fully aliphatic polyamides having a melting point of at least 250° C. in a weight ratio from about 20:80 to about 30:70.
  • Polyamides are condensation products of one or more dicarboxylic acids and one or more diamines, and/or one or more aminocarboxylic acids, and/or ring-opening polymerization products of one or more cyclic lactams.
  • the two or more fully aliphatic polyamides are formed from aliphatic and alicyclic monomers such as diamines, dicarboxylic acids, lactams, aminocarboxylic acids, and their reactive equivalents.
  • a suitable aminocarboxylic acid is 11-aminododecanoic acid.
  • Suitable lactams include caprolactam and laurolactam.
  • the term “fully aliphatic polyamide” also refers to copolymers derived from two or more such monomers and blends of two or more fully aliphatic polyamides. Linear, branched, and cyclic monomers may be used.
  • Carboxylic acid monomers comprised in the fully aliphatic polyamides are aliphatic carboxylic acids, such as for example adipic acid (C6), pimelic acid (C7), suberic acid (C8), azelaic acid (C9), sebacic acid (C10), dodecanedioic acid (C12) and tetradecanedioic acid (C14).
  • the aliphatic dicarboxylic acids of the fully aliphatic polyamides are selected from adipic acid and dodecanedioic acid.
  • the fully aliphatic polyamides described herein comprise an aliphatic diamine as previously described.
  • the one or more diamine monomers of the two or more fully aliphatic polyamide copolymer according to the present invention are selected from tetramethylene diamine and hexamethylene diamine.
  • Suitable examples of fully aliphatic polyamides are poly(hexamethylene adipamide (also called polyamide 6,6; polyamide 66, PA66, or nylon 66), and poly(tetramethylene adipamide) (also called polyamide 4,6, polyamide 46, PA46, or nylon 46), and any copolymers and combinations of the 2, or of either or both with other polyamides, provided that the copolymer has at least 250° C. melting point.
  • Suitable polyamides having a melting point of at least 250° C. are polyamides selected from the group poly(hexamethylene hexanediamide) (PA 66), poly( ⁇ -caprolactam/hexamethylene hexanediamide) (PA6/66), (PA6/66/610), poly( ⁇ -caprolactam/hexamethylene hexanediamide/hexamethylene dodecanediamide) (PA6/66/612), poly( ⁇ -caprolactam/hexamethylene hexanediamide/hexamethylene decanediamide/hexamethylene dodecanediamide) (PA6/66/610/612), poly(2-methylpentamethylene hexanediamide/hexamethylene hexanediamide/) (PA D6/66), poly(tetramethylene hexanediamide) (PA46).
  • Preferred examples of fully aliphatic polyamides useful in the polyamide composition of the present invention are PA66 and
  • An embodiment of the current invention comprises a matrix resin composition and a surface resin composition comprising a blend of poly(tetramethylene hexanediamide) (PA46) with one or more fully aliphatic polyamides having a melting point of at least 250° C.
  • PA46 poly(tetramethylene hexanediamide)
  • a preferred embodiment of the current invention comprise a matrix resin composition comprising a blend of poly(tetramethylene hexanediamide) (PA46) with poly(hexamethylene hexanediamide) (PA66).
  • Another preferred embodiment of the current invention comprise a matrix resin composition comprising a blend of poly(tetramethylene hexanediamide) (PA46) with poly(hexamethylene hexanediamide) (PA66) in a ratio of 50:50.
  • PA46 poly(tetramethylene hexanediamide)
  • PA66 poly(hexamethylene hexanediamide)
  • the surface resin composition described herein and/or the matrix resin composition may further comprise one or more impact modifiers, one or more heat stabilizers, one or more oxidative stabilizers, one or more ultraviolet light stabilizers, one or more flame retardant agents or mixtures thereof.
  • the surface resin composition described herein and/or the matrix resin composition may further comprise one or more reinforcing agents such as glass fibers, glass flakes, carbon fibers, carbon nanotubes, mica, wollastonite, calcium carbonate, talc, calcined clay, kaolin, magnesium sulfate, magnesium silicate, boron nitride, barium sulfate, titanium dioxide, sodium aluminum carbonate, barium ferrite, and potassium titanate.
  • reinforcing agents such as glass fibers, glass flakes, carbon fibers, carbon nanotubes, mica, wollastonite, calcium carbonate, talc, calcined clay, kaolin, magnesium sulfate, magnesium silicate, boron nitride, barium sulfate, titanium dioxide, sodium aluminum carbonate, barium ferrite, and potassium titanate.
  • the one or more reinforcing agents are present in an amount from at or about 1 to at or about 60 wt-%, preferably from at or about 1 to at or about 40 wt-%, or more preferably from at or about 1 to at or about 35 wt-%, the weight percentages being based on the total weight of the surface resin composition or the matrix resin composition, as the case may be.
  • the matrix resin composition and the surface resin composition may be identical or different.
  • the melt viscosity of the compositions may be reduced and especially the melt viscosity of the matrix resin composition.
  • the surface resin composition described herein and/or the matrix resin composition may further comprise modifiers and other ingredients, including, without limitation, flow enhancing additives, lubricants, antistatic agents, coloring agents (including dyes, pigments, carbon black, and the like), nucleating agents, crystallization promoting agents and other processing aids known in the polymer compounding art.
  • modifiers and other ingredients including, without limitation, flow enhancing additives, lubricants, antistatic agents, coloring agents (including dyes, pigments, carbon black, and the like), nucleating agents, crystallization promoting agents and other processing aids known in the polymer compounding art.
  • Fillers, modifiers and other ingredients described above may be present in the composition in amounts and in forms well known in the art, including in the form of so-called nano-materials where at least one of the dimensions of the particles is in the range of 1 to 1000 nm.
  • the surface resin compositions and the matrix resin compositions are melt-mixed blends, wherein all of the polymeric components are well-dispersed within each other and all of the non-polymeric ingredients are well-dispersed in and bound by the polymer matrix, such that the blend forms a unified whole.
  • Any melt-mixing method may be used to combine the polymeric components and non-polymeric ingredients of the present invention.
  • the polymeric components and non-polymeric ingredients may be added to a melt mixer, such as, for example, a single or twin-screw extruder; a blender; a single or twin-screw kneader; or a Banbury mixer, either all at once through a single step addition, or in a stepwise fashion, and then melt-mixed.
  • a melt mixer such as, for example, a single or twin-screw extruder; a blender; a single or twin-screw kneader; or a Banbury mixer, either all at once through a single step addition, or in a stepwise fashion, and then melt-mixed.
  • a melt mixer such as, for example, a single or twin-screw extruder; a blender; a single or twin-screw kneader; or a Banbury mixer, either all at once through a single step addition, or in a stepwise fashion, and then melt-mixed.
  • the composite structure according to the present invention may have any shape.
  • the composite structure according to the present invention is in the form of a sheet structure.
  • the composite structure may be flexible, in which case it can be rolled.
  • the composite structure can be made by a process that comprises a step of impregnating the fibrous material with the matrix resin composition, wherein at least a portion of the surface of the composite structure, is made of the surface resin composition.
  • the fibrous material is impregnated with the matrix resin by thermopressing. During thermopressing, the fibrous material, the matrix resin composition and the surface resin composition undergo heat and pressure in order to allow the resin compositions to melt and penetrate through the fibrous material and, therefore, to impregnate said fibrous material.
  • thermopressing is made at a pressure between 2 and 100 bars and more preferably between 10 and 40 bars and a temperature which is above the melting point of the matrix resin composition and the surface resin composition, preferably at least about 20° C. above the melting point to enable a proper impregnation.
  • Heating may be done by a variety of means, including contact heating, radiant gas heating, infra red heating, convection or forced convection air heating, induction heating, microwave heating or combinations thereof.
  • the impregnation pressure can be applied by a static process or by a continuous process (also known as dynamic process), a continuous process being preferred for reasons of speed.
  • impregnation processes include without limitation vacuum molding, in-mold coating, cross-die extrusion, pultrusion, wire coating type processes, lamination, stamping, diaphragm forming or press-molding, lamination being preferred.
  • heat and pressure are applied to the fibrous material, the matrix resin composition and the surface resin composition through opposing pressured rollers or belts in a heating zone, preferably followed by the continued application of pressure in a cooling zone to finalize consolidation and cool the impregnated fibrous material by pressurized means.
  • lamination techniques include without limitation calendering, flatbed lamination and double-belt press lamination. When lamination is used as the impregnating process, preferably a double-belt press is used for lamination.
  • the surface resin composition always faces the environment of the first component so as to be accessible when the overmolding resin composition is applied onto the composite structure.
  • the matrix resin composition and the surface resin composition are applied to the fibrous material by conventional means such as for example powder coating, film lamination, extrusion coating or a combination of two or more thereof, provided that the surface resin composition is applied on at least a portion of the surface of the composite structure, which surface is exposed to the environment of the first component.
  • a polymer powder which has been obtained by conventional grinding methods is applied to the fibrous material.
  • the powder may be applied onto the fibrous material by scattering, sprinkling, spraying, thermal or flame spraying, or fluidized bed coating methods.
  • the powder coating process may further comprise a step which consists in a post sintering step of the powder on the fibrous material.
  • the matrix resin composition and the surface resin composition are applied to the fibrous material such that at least a portion of the surface of the first component is made of the surface resin composition.
  • thermopressing is performed on the powder coated fibrous material, with an optional preheating of the powder coated fibrous material outside of the pressurized zone.
  • one or more films made of the matrix resin composition and one or more films made of the surface resin composition which have been obtained by conventional extrusion methods known in the art such as for example blow film extrusion, cast film extrusion and cast sheet extrusion are applied to the fibrous material, e.g. by layering.
  • thermopressing is performed on the assembly comprising the one or more films made of the matrix resin composition and the one or more films made of the surface resin composition and the one or more fibrous materials.
  • the films melt and penetrate around the fibrous material as a polymer continuum surrounding the fibrous material.
  • pellets and/or granulates made of the matrix resin composition and pellets and/or granulates made of the surface resin composition are melted and extruded through one or more flat dies so as to form one or more melt curtains which are then applied onto the fibrous material by laying down the one or more melt curtains. Subsequently, thermopressing is performed on the assembly comprising the matrix resin composition, the surface resin composition and the one or more fibrous materials.
  • the composite structure obtained under step i) may be shaped into a desired geometry or configuration, or used in sheet form.
  • the process for making a composite structure according to the present invention may further comprise a step ii) of shaping the composite structure, said step arising after the impregnating step i).
  • the step of shaping the composite structure obtained under step i) may be done by compression molding, stamping or any technique using heat and/or pressure. Preferably, pressure is applied by using a hydraulic molding press.
  • the composite structure is preheated to a temperature above the melt temperature of the surface resin composition and is transferred to a forming or shaping means such as a molding press containing a mold having a cavity of the shape of the final desired geometry whereby it is shaped into a desired configuration and is thereafter removed from the press or the mold after cooling to a temperature below the melt temperature of the surface resin composition and preferably below the melt temperature the matrix resin composition.
  • a forming or shaping means such as a molding press containing a mold having a cavity of the shape of the final desired geometry whereby it is shaped into a desired configuration and is thereafter removed from the press or the mold after cooling to a temperature below the melt temperature of the surface resin composition and preferably below the melt temperature the matrix resin composition.
  • the composite structure of the invention is particularly suited to overmolding with a polyamide overmolding resin composition.
  • Any polyamide resin can be used for the overmolding resin composition.
  • the composite structures according to the present invention may be used in a wide variety of applications such as for example as components for automobiles, trucks, commercial airplanes, aerospace, rail, household appliances, computer hardware, hand held devices, recreation and sports, structural component for machines, structural components for buildings, structural components for photovoltaic equipments or structural components for mechanical devices.
  • automotive applications include without limitation seating components and seating frames, engine cover brackets, engine cradles, suspension arms and cradles, spare tire wells, chassis reinforcement, floor pans, front-end modules, steering column frames, instrument panels, door systems, body panels (such as horizontal body panels and door panels), tailgates, hardtop frame structures, convertible top frame structures, roofing structures, engine covers, housings for transmission and power delivery components, oil pans, airbag housing canisters, automotive interior impact structures, engine support brackets, cross car beams, bumper beams, pedestrian safety beams, firewalls, rear parcel shelves, cross vehicle bulkheads, pressure vessels such as refrigerant bottles and fire extinguishers and truck compressed air brake system vessels, hybrid internal combustion/electric or electric vehicle battery trays, automotive suspension wishbone and control arms, suspension stabilizer links, leaf springs, vehicle wheels, recreational vehicle and motorcycle swing arms, fenders, roofing frames and tank flaps.
  • automotive applications include without limitation seating components and seating frames, engine cover brackets, engine cradles, suspension arms and cradles, spare tire well
  • Examples of household appliances include without limitation washers, dryers, refrigerators, air conditioning and heating.
  • Examples of recreation and sports include without limitation inline-skate components, baseball bats, hockey sticks, ski and snowboard bindings, rucksack backs and frames, and bicycle frames.
  • Examples of structural components for machines include electrical/electronic parts such as for example housings for hand held electronic devices, computers.
  • Polyamide 1 (PA1 in Tables): an aliphatic polyamide, poly(tetramethylene hexanediamide). This polyamide is called PA46 and is commercially available, for example, from DSM corporation. PA1 has a melting point of about 275° C. to about 290° C.
  • Polyamide 2 (PA2 in Tables): an aliphatic polyamide made of adipic acid and 1,6-hexamethylenediamine with a weight average molecular weight of around 32000 Daltons. This polyamide is called PA6,6 and is commercially available, for example, from E. I. du Pont de Nemours and Company. PA2 has a melting point of about 260° C. to about 265° C.
  • the resin compositions used in the Examples (abbreviated as “E” in Tables 1 and 2), and Comparative Examples (abbreviated as “C” in Tables 1 and 2) were prepared by melting or melt-blending the ingredients in a twin-screw extruder at about 300° C. in the case of the matrix resin and the surface resin compositions of E1 and C1 and the surface resin composition of E2 and C3, or at about 280° C. in the case of the matrix resin compositions of E2 and C2 to C4, and the matrix the surface resin composition of C2 and C4.
  • Preparation of the composite structures E1, C1, and C2 in Table 1 was accomplished by laminating multiple layers of film of compositions shown in Table 1 and woven continuous glass fiber textile (prepared from E-glass fibers having a diameter of 17 microns, sized with 0.4% of a silane-based sizing agent and a nominal roving tex of 1200 g/km that have been woven into a 2/2 twill (balanced weave) with an areal weight of 600 g/m 2 ) in the following sequence for E1 and C1: 4 layers of film of surface resin composition, one layer of woven continuous glass fiber textile, 4 layers of film of matrix resin composition, one layer of woven continuous glass fiber textile, four layers of film of matrix resin composition, one layer of woven continuous glass fiber textile, and four layers of film of surface resin composition; and in the following sequence for C2: two layers of film of surface resin composition, one layer of woven continuous glass fiber textile, two layers of film of matrix resin composition, one layer of woven continuous glass fiber textile, two layers of film of
  • the composite structures of table 1 were compression molded by a Dake Press (Grand Haven, Mich.) Model 44-225, Pressure range 0-25K, with an 8 inch platten.
  • a 6 ⁇ 6′′ specimen of film and glass textile layers as described above was placed in the mold and heated to a temperature of about 320° C., held at the temperature for 2 minutes without pressure, then pressed at the 320° C. temperature with the following pressures: about 4 bar for about 2 minutes, then with about 12 bar for about 2 additional minutes, and then with about 20 bar for about 2 additional minutes; they were subsequently cooled to ambient temperature.
  • the thusly formed composite structures had a thickness of about 1.6 mm, and glass fiber content in the range of 55 to 60 percent of the total weight of the composite structure.
  • the composite structures E2, C3, and C4 were prepared by first making a laminate by stacking eight layers having a thickness of about 102 microns and made of PA2 and three layers of woven continuous glass fiber textile (E-glass fibers having a diameter of 17 microns, 0.4% of a silane-based sizing and a nominal roving tex of 1200 g/km that have been woven into a 2/2 twill (balanced weave) with an areal weight of 600 g/m 2 ) in the following sequence: two layers made of PA2, one layer of woven continuous glass fiber textile, two layers of PA2, one layer of woven continuous glass fiber textile, two layers of PA2, one layer of woven continuous glass fiber textile and two layers of PA2.
  • woven continuous glass fiber textile E-glass fibers having a diameter of 17 microns, 0.4% of a silane-based sizing and a nominal roving tex of 1200 g/km that have been woven into a 2/2 twill (balanced weave) with an
  • the laminates were prepared using an isobaric double press machine with counter rotating steel belts, both supplied by Held GmbH. The different films enterered the machine from unwinders in the previously defined stacking sequence. The heating zones were about 2000 mm long and the cooling zones were about 1000 mm long. Heating and cooling were maintained without release of pressure.
  • the laminates were prepared with the following conditions: a lamination rate of 1 m/min, a maximum machine temperature of 360° C. and laminate pressure of 40 bar. The so-obtained laminates had an overall thickness of about 1.5 mm.
  • the composite structures comprising a surface made of the surface polyamide resin compositions of E2 or C3 or C4 described in Table 2, the matrix resin compositions PA2 and the fibrous material had an overall thickness of about 1.6 mm.
  • the composite structures E1, C1, and C2 in Table 1 were cut into 1 ⁇ 2′′ (about 12.7 mm) by 2.5′′ (about 64 mm) long test specimens (bars) using a MK-377 Tile Saw with a diamond edged blade and water as a lubricant. Flexural Strength was tested on the test specimens via a 3-point bend test.
  • the apparatus and geometry were according to ISO method 178, bending the specimen with a 2.0′′ support width with the loading edge at the center of the span. The tests were conducted with 1 KN load at 2 mm/min until fracture.
  • the over-injection molding was accomplished by over-injecting 1.8 mm of the overmolding resin composition onto the composite structures obtained as described above.
  • the composite structures E2, C3, and C4 comprising a surface made of the surface resin compositions listed in Table 2, the matrix resin compositions listed in Table 2 and the fibrous material described above were cut into 5 ⁇ 5′′ (about 127 mm ⁇ 127 mm) specimens and placed into a heating chamber for 3 min at 210° C. Then the composite structures were quickly transferred with a robot arm into a mold cavity of an Engel vertical press and were over injection molded with the overmolding resin composition comprising PA2 and 50 weight percent of glass fibers (percentage of the total composition of the overmolding resin) by an Engel molding machine. The transfer time from leaving the heating chamber to contact with the overmolding resin was 9 sec.
  • the mold was oil heated at 120° C.
  • the injection machine was set at 280° C.
  • the 5 ⁇ 5′′ specimens of the overmolded composite structures comprising E2, C3, and C4 prepared as described above, were cut into 1 ⁇ 2′′ (about 12.7 mm) ⁇ 3′′ (about 76 mm) test specimens, and were notched by cutting the overmolded part up to the interface of the overmolded part and the composite structure.
  • the notch was made through the width at about the middle (lengthwise) of the test specimen.
  • the bond strength of the overmolded resin composition to the composite structure was measured on the notched test specimens via a 3 point bend method, modified ISO-178.
  • the apparatus and geometry were according to ISO method 178, bending the specimen with a 2.0′′ (about 51 mm) support width with the loading edge at the center of the span.
  • the over-molded part of the specimen was on the tensile side (outer span) resting on the two side supports (at 2′′ (about 51 mm) apart), while indenting with the single support (the load) on the compression side (inner span) on the composite structure of the specimen.
  • the notch in the specimens was down (tensile side).
  • the notch was placed 1 ⁇ 4′′ off center (1 ⁇ 4′′ away from the load).
  • the tests were conducted at 2 mm/min with a 1 KN load. The test was run until a separation or fracture between the two parts of the specimen (delamination) was seen. The stress at that point was recorded.

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  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
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  • Inorganic Chemistry (AREA)
  • Reinforced Plastic Materials (AREA)
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  • Compositions Of Macromolecular Compounds (AREA)
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  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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