Multilayer composite material containing special polycarbonate compositions as a matrix material

Patent metadata

Field	Value
Publication number	US-11993061-B2
Application number	US-202117538218-A
Country	US
Kind code	B2
Filing date	Nov 30, 2021
Priority date	Jul 4, 2016
Publication date	May 28, 2024
Grant date	May 28, 2024

Abstract

Multilayer composite material comprising specific polycarbonate compositions as matrix material 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 process for producing a layer of fibre composite material, wherein a molten, aromatic polycarbonate-based composition comprising
A) aromatic polycarbonate,
B) 1% by weight to 14% by weight of talc,
C) 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,
D) 0% to 11% by weight of at least one phosphorus compound of general formula (V)

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;
E) 0% to 0.2% by weight of at least one stabilizer selected from a group consisting of alkyl phosphate, ethylenediaminetetraacetic acid and citric acid,
wherein the composition is free of PTFE,
is applied to a raw fibre tape composed of fibre material that has been preheated to above the glass transition temperature of the polycarbonate.

2. A process for producing a multilayer composite material, 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, aromatic polycarbonate-based composition comprising
A) aromatic polycarbonate,
B) 1% by weight to 14% by weight of talc,
C) 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, D) 0% to 11% by weight of at least one phosphorus compound of general formula (V)

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; E) 0% to 0.2% by weight of at least one stabilizer selected from a group consisting of alkyl phosphate, ethylenediaminetetraacetic acid and/or citric acid,
wherein the composition is free of PTFE, to a raw fibre tape composed of fibre material that has been preheated to above the glass transition temperature of the polycarbonate,
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 composite material.

3. The process according to claim 1 , wherein the composition is applied to the raw fibre tape under pressure-shear vibration.

4. The process according to claim 1 , wherein the fibre material is selected from a group consisting of carbon fibres, glass fibres, basalt fibres and mixtures thereof and comprises endless fibres, a weave or a knit.

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

6. The process according to claim 1 , wherein the composition comprises 3% to 12% by weight of talc, 10% to 13% by weight of phosphazene as per component C and 2% to 10% by weight of at least one phosphorus compound of the general formula (V) as per component D.

7. The process according to claim 2 , 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.

8. 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 at a 0° orientation with respect thereto.

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

10. 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.

11. The process according to claim 1 , wherein the molten, aromatic polycarbonate-based composition further comprises further additives.

Assignees

• Covestro Deutschland Ag

Inventors

• Wehrmann Rolf
• Boumans Anke
• Heuer Helmut Werner
• Grimm Thomas
• Knaupp Matthias
• Bauer John

Classifications

• B32B27/12 Primary

  next to a fibrous or filamentary layer · CPC title

• B05D3/0218

  Pretreatment, e.g. heating the substrate · CPC title

• B29C65/02

  by heating, with or without pressure · CPC title

• B29C65/44

  Joining a heated non plastics element to a plastics element · CPC title

• B32B5/024

  Woven fabric · CPC title