Multilayer composite material containing special polycarbonate compositions as a matrix material

Patent metadata

Field	Value
Publication number	US-11505665-B2
Application number	US-201816956546-A
Country	US
Kind code	B2
Filing date	Dec 12, 2018
Priority date	Dec 19, 2017
Publication date	Nov 22, 2022
Grant date	Nov 22, 2022

Abstract

The present invention relates to a composite material comprising one or more fibre layers composed of a fibre material and an aromatic polycarbonate-based matrix material. The fibre layer(s) is/are embedded in the matrix material. The present invention further relates to a process for producing these fibre composite materials, to multilayer composite materials comprising several layers of fibre composite material, and to the use of the composite materials for production of components or housing components or housings, and to the components, housing components or housings themselves.

First claim

The invention claimed is:

1. A fibre composite material comprising at least one layer of fibre material embedded into a composition wherein the composition comprises
A) at least 65% by weight of at least one aromatic polycarbonate,
B) 7% by weight to 15% by weight of at least one cyclic phosphazene of formula (1)

where
R is the same or different and is an amine radical, and in each case optionally halogenated C 1 - to C 8 -alkyl radical, C 1 - to C 8 -alkoxy radical, in each case optionally alkyl- and/or halogen-substituted C 5 - to C 6 -cycloalkyl radical, in each case optionally alkyl- and/or halogen- and/or hydroxyl-substituted C 6 - to C 20 - aryloxy radical, in each case optionally alkyl- and/or halogen-substituted C 7 - to C 12 -aralkyl radical or a halogen radical or an OH radical,
k is an integer from 1 to 10,

C) 0% to 11% by weight of at least one phosphorus compound of the general formula (2)

where
R 1 , R 2 , R 3 and R 4 are each independently a C 1 - to C 8 -alkyl radical, in each case optionally halogenated and in each case branched or unbranched, and/or C 5 - to C 6 -cycloalkyl radical, C 6 - to C 20 -aryl radical or C 7 - to C 12 -aralkyl radical, in each case optionally substituted by branched or unbranched alkyl and/or halogen,

n is independently 0 or 1,
q is an integer from 0 to 30,
X is a mono- or polycyclic aromatic radical having 6 to 30 carbon atoms or a linear or branched aliphatic radical having 2 to 30 carbon atoms, each of which may be substituted or unsubstituted, and bridged or unbridged,
and wherein the composition is free of anti-dripping agents and free of talc, and wherein a total of at least 14% by weight of component B+component C is present, based on the overall composition.

2. The fibre composite material according to claim 1 , wherein the fibre material is selected from the group consisting of carbon fibres, glass fibres, basalt fibres and mixtures thereof.

3. The fibre composite material according to claim 1 , wherein the fibre material is an endless fibre material, a woven fibre material or a knitted fibre material.

4. The fibre composite material according to claim 1 , wherein the fibre material are endless fibres and the endless fibres are aligned unidirectionally.

5. The fibre composite material according to claim 1 , wherein the composition comprises
A) at least 75% by weight of at least one aromatic polycarbonate,
B) 7% by weight to 12% by weight of at least one cyclic phosphazene of formula (1),
C) 4% by weight to 10% by weight of at least one phosphorus compound of the general formula (2).

6. The fibre composite material according to claim 1 , wherein the composition does not contain any inorganic fillers.

7. The fibre composite material according to claim 1 , wherein the composition consists of
A) 75% by weight to 87% by weight of at least one aromatic polycarbonate,
B) 8% by weight to 10% by weight of at least one cyclic phosphazene of formula (1), wherein the cyclic phosphazene of component B present is at least phenoxyphosphazene,
C) 5% to 7% by weight of at least one phosphorus compound of the general formula (2) wherein the only phosphorus compound of the formula (2) present is the phosphorus compound of the formula (2b)

with an average q value q=1.0 to 1.2,

D) 0% to 10% by weight of one or more further additives other than components B and C, selected from the group consisting of UV stabilizers, IR absorbers, antioxidants, demoulding agents, flow auxiliaries, antistats, impact modifiers, colourants, thermal stabilizers, further flame retardants,
and the fibre material comprises unidirectionally oriented endless carbon fibres.

8. The fibre composite material according to claim 7 , wherein the sole cyclic phosphazene of the formula (1) present is phenoxyphosphazene and the proportion of cyclic phosphazene with k=1 is 50 to 98 mol %, based on the total amount of cyclic phosphazene of the formula (1).

9. A multilayer composite material comprising at least two mutually superposed layers of the fibre composite material according to claim 1 .

10. The multilayer composite material according to claim 9 , comprising at least three mutually superposed layers the fibre composite material which 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 the inner layers of fibre composite material have essentially the same orientation and the orientation thereof relative to the outer layers of fibre composite material is rotated by 30° to 90° , wherein the orientation of one layer of fibre composite material is determined by the orientation of the unidirectionally aligned fibres present therein.

11. The process for producing a multilayer composite material according to claim 9 , comprising the following steps:
providing at least one inner layer of fibre composite material and two outer layers of fibre composite material, wherein the individual layers of fibre composite material are produced by applying a molten composition comprising
A) at least 65% by weight of at least one aromatic polycarbonate,
B) 7% by weight to 15% by weight of at least one cyclic phosphazene of formula (1)

where
R is the same or different and is an amine radical, an in each case optionally halogenated C 1 - to C 8 -alkyl radical, C 1 - to C 8 -alkoxy radical, in each case optionally alkyl- and/or halogen-substituted C 5 - to C 6 -cycloalkyl radical, in each case optionally alkyl- and/or halogen- and/or hydroxyl-substituted C 6 - to C 20 -aryloxy radical, in each case optionally alkyl- and/or halogen-substituted C 7 - to C 12 -aralkyl radical or a halogen radical or an OH radical,
k is an integer from 1 to 10,

C) 0% to 11% by weight of at least one phosphorus compound of the general formula (2)

where
R 1 , R 2 , R 3 and R 4 are each independently a C 1 - to C 8 -alkyl radical, in each case optionally halogenated and in each case branched or unbranched, and/or C 5 - to C 6 -cycloalkyl radical, C 6 - to C 20 -aryl radical or C 7 - to C 12 -aralkyl radical, in each case optionally substituted by branched or unbranched alkyl and/or halogen,
n is independently 0 or 1,
q is an integer from 0 to 30,
X is a mono- or polycyclic aromatic radical having 6 to 30 carbon atoms or a linear or branched aliphatic radical having 2 to 30 carbon atoms, each of which may be substituted or unsubstituted, and bridged or unbridged,
to a raw fibre tape composed of fibre material that has been preheated to above the glass transition temperature of the polycarbonate, wherein the composition is applied to the raw fibre tape under pressure-shear vibration,
layering the layers of fibre composite material in the desired orientation relative to one another, based on the orientation of the fibre material,
bonding the layered layers of fibre composite material to form the multilayer compos

Assignees

• Covestro Deutschland Ag

Inventors

• Wehrmann Rolf
• Heuer Helmut Werner
• Boumans Anke
• Bauer John

Classifications

• C08K5/5399

  Phosphorus bound to nitrogen · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• C08J2369/00

  Characterised by the use of polycarbonates; Derivatives of polycarbonates · CPC title

• B29C70/465

  and impregnating by melting a solid material, e.g. sheets, powders of fibres · CPC title

• B29C70/202

  arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] (B29C70/207 takes precedence) · CPC title