STRUCTURAL ORGANOSHEET-COMPONENT

• US 20110020572A1
• Filed: 07/20/2010
• Published: 01/27/2011
• Est. Priority Date: 07/25/2009
• Status: Abandoned Application

• Current Assignee: Lanxess Deutschland GmbH (Lanxess AG)
• Original Assignee: Lanxess Deutschland GmbH (Lanxess AG)
• Inventors: ZIMNOL, Ralf, DAJEK, Ulrich, HASPEL, Julian, WAMBACH, Wolfgang, MALEK, Thomas
• Application Number:
  US12/839,926
• Publication Number:
  US 20110020572A1
• Time in Patent Office: Days
• US Class Current: 428/35.7
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2272/00 Resin or rubber layer comprising scrap, waste or recycling material
• CPC Class Codes: B32B 2307/308 Heat stability dimensional stability B32B2307/734
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/544 Torsion strength; Torsion stiffness
• CPC Class Codes: B32B 2307/708 Isotropic
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/16 : specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/22 : using plasticisers
• CPC Class Codes: B32B 27/281 : comprising polyimides
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/147 : by treatment of the layer
• CPC Class Codes: B60N 2/68 : Seat frames
• CPC Class Codes: B60N 2/686 : Panel like structures
• CPC Class Codes: C08L 101/005 : Dendritic macromolecules
• CPC Class Codes: C08L 23/0869 : Acids or derivatives thereof
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

The present invention relates to structural organosheet-components of hybrid design composed of an organosheet which is reinforced by means of thermoplastics and which is suitable for the transmission of high mechanical loads, where particular flow aids are added to the thermoplastic in order to improve its physical properties.

Claims

1. A structural organosheet-component composed of polymer-overmolded organosheet, wherein the backing material used comprises polymer molding compositions comprising

A) from 99.99 to 10 parts by weight of thermoplastic, and

B) from 0.01 to 50 parts by weight of a flow improver selected from the group consisting of B1), B2), B3), and B4), and

B1) is a copolymer composed of at least one olefin, and of at least one methacrylate or acrylate of an aliphatic alcohol, where the MFI is not less than 100 g/10 min, and where the MFI (melt flow index) is measured or determined at 190°

C., using a test weight of 2.16 kg,

B2) is a highly branched or hyperbranched polycarbonate with an OH number of from 1 to 600 mg KOH/g of polycarbonate (to DIN 53240, Part

     2),

B3) is a highly branched or hyperbranched polyester of A_xB_y type, where x is at least 1.1 and y is at least 2.1, and

B4) is a low-molecular-weight polyalkylene glycol ester (PAGE) of the formula (I)

R—

COO—

(Z—

O)_nOC—

R  

 

(I)

in which

R is a branched or straight-chain alkyl group having from 1 to 20 carbon atoms,

Z is a branched or straight-chain C₂-C₁₅-alkylene group, and

n is a whole number from 2 to 20,

or wherein, irrespective of the use of a component B), the thermoplastics used comprise polyamides having macromolecular chains with star-shaped structure and having linear macromolecular chains.

2. A structural organosheet-component as claimed in claim 1, wherein, in the case of the use of polyamides having macromolecular chains of star-shaped structure and having linear macromolecular chains, this material comprises a mixture of

a) monomers of the formula (II) R₁-(-D-Z)_m,

b) monomers of the formula ((IIIa) X—

R₂—

Y and

3. A structural organosheet-component as claimed in claim 1, wherein the secure interlock bond between molded-on thermoplastic and the organosheet is additionally achieved by way of discrete connection sites by way of perforations in the parent organosheet body, where the thermoplastic extends through these and across the area of the perforations.

4. A structural organosheet-component as claimed in claim 1, wherein the parent organosheet body has the shape of a shell.

5. A structural organosheet-component as claimed in claim 1, wherein molding compositions comprising components A) and B) and C) from 0.001 to 75 parts by weight of a filler or reinforcing material are used during production.

6. A structural organosheet-component as claimed in claim 5, comprising glass fibers as filler or as reinforcing material.

8. A structural component for automotive or non-automotive applications, comprising the structural organosheet-components as claimed in claim 1.

9. A structural component according to claim 8, wherein the automotive sector and the non-automotive-sector are motor vehicles, rail vehicles, aircraft, ships, sleds or other means of conveyance, or electrical or electronic equipment, household equipment, furniture, heaters, motor scooters, shopping trolleys, shelving, staircases, escalator steps, or manhole covers.

10. Automotive roof structures, column structures, chassis structures, longitudinal-member structures, or front-end structures, front-end modules, headlamp frames, lock members, transverse members, radiator members and/or assembly supports, pedal structures, pedal block and/or pedal modules, door structures and flap structures, for instrument-panel-support structures, oil pans, seat structures, pedestrian-protection beams, specific slam panels for engine hoods, sliding-roof-support parts, dashboard-support parts (cross car beam), steering-column retainers, firewall, gear-shift blocks, B-column modules, jointing elements for the connection of longitudinal members and B-columns, and of transverse members, wheel surrounds, wheel-surround modules, crash boxes, rear ends, spare-wheel recesses, engine hoods, engine-oil pans, water-tank assemblies, engine-rigidity systems (front-end rigidity system), chassis components, vehicle floors, sills, sill-reinforcement systems, floor-regidity systems, seat-regidity system, transverse seat members, frames, seat shells, seat backrests with or without integrated safety belt, parcel shelves, complete vehicle-door structures, jointing elements for the connection of A-column and transverse members, jointing elements for the connection of A-column, transverse member, and floor-rigidity systems, transverse seat members, valve covers, end-shields for generators or electric motors comprising the structural organosheet-component of claim 1.

7. A process for the production of a structural organosheet-component with an organosheet having reinforcing structures, bonded to the parent body and being composed of molded-on polymer, which comprises using polymer molding compositions comprising

A) from 99.99 to 10 parts by weight of thermoplastic, and

B) from 0.01 to 50 parts by weight of a flow improver, wherein the flow improver is at least one component selected from the group consisting of B1), B2), B3), and B4), in which

B1) is a copolymer composed of at least one olefin and of at least one methacrylate or acrylate of an aliphatic alcohol, where the MFI (melt flow index) thereof is not less than 100 g/10 min, and the MFI is measured or determined at 190°

C., using a load of 2.16 kg,

B2) is a highly branched or hyperbranched polycarbonate with an OH number of from 1 to 600 mg KOH/g of polycarbonate (to DIN 53240, Part

     2),

B3) is a highly branched or hyperbranched polyester of A_xB_y type, where x is at least 1.1 and y is at least 2.1, and

B4) is a low-molecular-weight polyalkylene glycol ester (PAGE) of the formula (I)

R—

COO—

(Z—

O)_nOC—

R  

 

(I)

in which

R is a branched or straight-chain alkyl group having from 1 to 20 carbon atoms,

Z is a branched or straight-chain C₂-C₁₅-alkylene group, and

n is a whole number from 2 to 20, or comprises using, as thermoplastic in injection-molding processes or extrusion processes, polyamides having macromolecular chains having a star-shaped structure and having linear, macromolecular chains.