Multi-layer composite material containing special copolycarbonates as a matrix material

Patent metadata

Field	Value
Publication number	US-11130321-B2
Application number	US-201716306252-A
Country	US
Kind code	B2
Filing date	May 31, 2017
Priority date	Jun 3, 2016
Publication date	Sep 28, 2021
Grant date	Sep 28, 2021

Abstract

The present invention relates to a composite material comprising one or more fibre layers of a fibre material, and a silicon-containing copolycarbonate as matrix material. The fibre layer(s) is/are embedded in the matrix material. The present invention further relates to a process for producing these composite materials and to the use thereof for production of construction or housing parts, and to the construction or housing parts themselves.

First claim

The invention claimed is:

1. A fibre composite material comprising at least one layer of fibre material, wherein the fibre materials are selected from glass fibres and/or carbon fibres as endless fibres or in the form of weaves and knits, embedded into a thermoplastic based on siloxane-containing block cocondensate, wherein the siloxane block has the following structure (4)

where R2 is independently a linear or branched aliphatic radical, or a substituted or unsubstituted aromatic radical,
n is 1 to 150, and m is 0 or 1,
R3 independently includes the following structure (5)

where R4 is independently hydrogen, halogen and/or in each case a C1 to C10, linear or branched, unsubstituted or mono- to tetrasubstituted alkyl radical or alkoxy radical, and
e is a natural number from 2 to 12, or
R3 is derived from hydroquinone, a substituted hydroquinone radical or a structural element of the formula (6)

where R6 and R7 are independently H, C1-C18-alkyl, C1-C18-alkoxy, halogen such as C1 or Br or in each case optionally substituted aryl or aralkyl, preferably independently H or C1-C12-alkyl, and
X is —CO—, —O—, —S—, C1- to C6-alkylene, C2- to C5-alkylidene, C6 to C10-cycloalkylidene or C6- to C12-arylene which may optionally be fused to further aromatic rings containing heteroatoms.

2. A multilayer composite material comprising at least two mutually superposed layers of fibre composite material according to claim 1 , wherein, in the case of three composite material layers, these are defined relative to one another as two outer layers of fibre composite material and at least one inner layer of fibre composite material, wherein, in the case of endless fibres as fibre material, these are aligned unidirectionally in the respective layer.

3. The multilayer composite material according to claim 2 , wherein the inner layers of fibre composite material have substantially the same orientation and their orientation is rotated by 30° to 90° relative to the outer layers of fibre composite material, wherein the orientation of one layer of fibre composite material is determined by the orientation of the unidirectionally aligned fibres present therein.

4. The multilayer composite material according to claim 2 , wherein at least some of the layers have the same orientation and at least some other layers are rotated by 30° to 90° and the outer layers are in a 0° orientation relative thereto.

5. The multilayer composite material according to claim 2 , wherein the inner layers have the same orientation and the orientation thereof is rotated by 30° to 90° relative to the outer layers of fibre composite material.

6. The multilayer composite material according to claim 2 , wherein the fibre volume content of the outer layers of fibre composite material is not more than 50% by volume, based on the volume of the outer layers of fibre composite material.

7. A process for producing the multilayer composite material according to claim 2 , comprising the following steps:
a) providing at least one inner layer of fibre composite material and two outer layers of fibre composite material, wherein the individual fibre composite material layers are produced by applying a molten siloxane-containing block cocondensate-based thermoplastic to a raw fibre belt preheated above the glass transition temperature of the siloxane-containing block cocondensate-based thermoplastic, with application under pressure-shear vibration,
b) inserting the at least one inner layer of fibre composite material between the outer fibre composite material layers, the inner layers of fibre composite material having the same orientation and the orientation thereof being rotated by 30° to 90° relative to the outer layers of fibre composite material,
c) bonding the layered layers of fibre composite material to give the multilayer composite material.

8. The fibre composite material according to claim 1 , wherein the structure of formula (4) is derived from one of the following structure (11) or (12):

where
R1 is hydrogen, Cl, Br or C1-C4-alkyl,
R2 is aryl, or C1-C4-alkyl,
X is a single bond, —SO2-, —CO—, —O—, —S—, C1- to C6-alkylene, C2- to C5-alkylidene, or C6- to C12-arylene which may optionally be fused to further aromatic rings containing heteroatoms, or C6-C12 cycloalkylidene,
n is an average number from 1 to 300 and
m is an average number from 1 to 10.

9. The fibre composite material according to claim 1 , wherein, for the construction of the siloxane-containing block cocondensate, the siloxane block has a molecular weight of 3000 to 20 000 g/mol.

10. A housing part or component obtained from the fibre composite material according to claim 1 .

11. A fibre composite material comprising at least one layer of fibre material, wherein the fibre materials are selected from glass fibres and/or carbon fibres as endless fibres or in the form of weaves and knits, embedded into a thermoplastic based on siloxane-containing block cocondensate, wherein the siloxane block has the following structure (10)

where
R5 is hydrogen or methyl,
R6 and R7 are independently methyl,
V is a single bond, O, C1 to C6-alkyl or C1 to C6-alkoxy,
W is a single bond, C1 to C6-alkylene, C2- to C5-alkylidene or C1 to C6-alkoxy,
Y is a single bond, —CO—, —O—, C1- to C6-alkylene, C2 to C5-alkylidene, a C5 to C6-cycloalkylidene radical which may be mono- or polysubstituted by C1 to C4-alkyl, or C6 to C12-arylene which may be fused to a further aromatic ring containing heteroatoms,
m is an average number of repeat units from 1 to 6,
o is an average number of repeat units from 10 to 400, and
p and q are each 0 or 1.

Assignees

• Covestro Deutschland Ag

Inventors

• Meyer Alexander
• Grimm Thomas
• Horn Klaus
• Kuhlmann Timo

Classifications

• C08F8/42 Primary

  Introducing metal atoms or metal-containing groups · CPC title

• B32B5/12

  characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} · CPC title

• C08L83/10

  Block- or graft-copolymers containing polysiloxane sequences (obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C08L51/08, C08L53/00) · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• B32B2260/046

  Synthetic resin · CPC title