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US20100029821A1 - Heat resistant thermoplastic articles including co-stabilizers - Google Patents

Heat resistant thermoplastic articles including co-stabilizers Download PDF

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Publication number
US20100029821A1
US20100029821A1 US12/512,172 US51217209A US2010029821A1 US 20100029821 A1 US20100029821 A1 US 20100029821A1 US 51217209 A US51217209 A US 51217209A US 2010029821 A1 US2010029821 A1 US 2010029821A1
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Prior art keywords
group
poly
hexamethylene
polyamides
terephthalamide
Prior art date
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Abandoned
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US12/512,172
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Inventor
Robert J. Palmer
Toshikazu Kobayashi
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EIDP Inc
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EI Du Pont de Nemours and Co
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Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to US12/512,172 priority Critical patent/US20100029821A1/en
Publication of US20100029821A1 publication Critical patent/US20100029821A1/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: KOBAYASHI, TOSHIKAZU, PALMER, ROBERT J.
Priority to US13/644,536 priority patent/US20130053483A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C08L77/06—Polyamides derived from polyamines and polycarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
    • C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
    • C08G69/26—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids
    • C08G69/265—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids from at least two different diamines or at least two different dicarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
    • C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
    • C08G69/26—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
    • C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
    • C08G69/36—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from amino acids, polyamines and polycarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013—Fillers, pigments or reinforcing additives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/005—Stabilisers against oxidation, heat, light, ozone
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/05—Alcohols; Metal alcoholates
    • C08K5/053—Polyhydroxylic alcohols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/06—Ethers; Acetals; Ketals; Ortho-esters
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/13—Phenols; Phenolates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C08K5/18—Amines; Quaternary ammonium compounds with aromatically bound amino groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C08L67/03—Polyesters derived from dicarboxylic acids and dihydroxy compounds the dicarboxylic acids and dihydroxy compounds having the carboxyl- and the hydroxy groups directly linked to aromatic rings
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/139—Open-ended, self-supporting conduit, cylinder, or tube-type article

Definitions

  • the present invention relates to the field of molded and extruded thermoplastic articles having improved long-term high temperature aging characteristics.
  • High temperature resins based on polyamides possess desirable chemical resistance, processability and heat resistance. This makes them particularly well suited for demanding high performance automotive and electrical/electronics applications.
  • the mechanical properties generally tend to decrease due to the thermo-oxidation of the polymer. This phenomenon is called heat aging.
  • heat stabilizers also referred as antioxidants
  • heat stabilizers include hindered phenol antioxidants, arrine antioxidants and phosphorus-based antioxidants.
  • heat stabilizers include hindered phenol antioxidants, arrine antioxidants and phosphorus-based antioxidants.
  • phenolic antioxidants optionally combined with a phosphorus based synergist as previously mentioned
  • aromatic amines optionally combined with a phosphorus based synergist
  • the third one is the use of copper salts and derivatives.
  • Phenolic antioxidants are known to improve the mechanical/physical properties of the thermoplastic composition up to an aging temperature of 120° C.
  • U.S. Pat. No. 5,965,652 discloses a thermally stable polyamide molding composition containing colloidal copper formed in situ. However, the disclosed compositions exhibit retention of impact strength only for a heat aging at 140° C.
  • GB patent 839,067 discloses a polyamide composition comprising a copper salt and a halide of a strong organic base.
  • the disclosed compositions exhibit improved bending heat stability performance only for a heat aging at 170° C.
  • compositions comprising a metal powder as thermal stabilizer with a fibrous reinforcing agent.
  • Disclosed compositions exhibit improved mechanical properties such as tensile strength and elongation at break upon long-term heat aging at 215° C.
  • metal powders are not only expensive but they are also highly unstable because they are prone to spontaneous combustion.
  • EP 1041109 discloses a polyamide composition
  • a polyamide composition comprising a polyamide resin, a polyhydric alcohol having a melting point of 150 to 280° C., that has good fluidity and mechanical strength and is useful in injection welding techniques.
  • thermoplastic article comprising a polyamide composition
  • polyamide composition comprising
  • thermoplastic article as disclosed above, wherein molded 4 mm test bars prepared from said polyamide composition, and exposed at a test temperature at 210° C. for a test period of 500 hours, in an atmosphere of air, and tested according to ISO 527-2/1A, have, on average, a retention of tensile strength of at least 50 percent, as compared with that of an unexposed control of identical composition and shape.
  • high-temperature means a temperature at or higher than 170° C., preferably at or higher than 210° C., and most preferably at or higher than 230° C.
  • long-term refers to an exposure period equal or longer than 500 hrs, preferably equal or longer than 1000 hrs.
  • the term “high heat stability”, as applied to the polyamide composition disclosed herein or to an article made from the composition, refers to the retention of physical properties (for instance, tensile strength) of 4 mm thick molded test bars consisting of the polyamide composition that are exposed to air oven aging (AOA) conditions at a test temperature at 170° C. for a test period of at least 500 h, in an atmosphere of air, and then tested according to ISO 527-2/1A method. The physical properties of the test bars are compared to that of unexposed controls that have identical composition and shape, and are expressed in terms of “% retention”.
  • AOA air oven aging
  • the test temperature is at 210° C.
  • the test period is at 500 hours and the exposed test bars have a % retention of tensile strength of at least 70%.
  • “high heat stability” means that said molded test bars, on average, meet or exceed a retention for tensile strength of 50% when exposed at a test temperature at 170° C. for a test period of at least 500 h. Compositions exhibiting a higher retention of physical properties for a given exposure temperature and time period have better heat stability.
  • At 170° C.” and “at 210° C.” refer to the nominal temperature of the environment to which the test bars are exposed; with the understanding that the actual temperature may vary by ⁇ 2° C. from the nominal test temperature.
  • (meth)acrylate is meant to include acrylate esters and methacrylate esters.
  • the polyamide resin used in the present invention has a melting point and/or glass transition.
  • melting points and glass transitions are 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 and the glass transition, if evident, is considered the mid-point of the change in enthalpy.
  • 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. Suitable cyclic lactams are caprolactam and laurolactam. Polyamides may be fully aliphatic or semi-aromatic.
  • Fully aliphatic polyamides used in the resin composition of the present invention 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 are 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 include, but are not limited to aliphatic carboxylic acids, such as for example adipic acid (C6), pimelic acid (C7), sijberic acid (C8), azelaic acid (C9), decanedioic acid (C10), dodecanedioic acid (C12), tridecanedioic acid (C13), tetradecanedioic acid (C14), and pentadecanedioic acid (C15).
  • aliphatic carboxylic acids such as for example adipic acid (C6), pimelic acid (C7), sijberic acid (C8), azelaic acid (C9), decanedioic acid (C10), dodecanedioic acid (C12), tridecanedioic acid (C13), tetradecanedioic acid (C14), and pentadecane
  • Diamines can be chosen among diamines having four or more carbon atoms, including, but not limited to tetramethylene diamine, hexamethylene diamine, octamethylene diamine, decamethylene diamine, dodecamethylene diamine, 2-methylpentamethylene diamine, 2-ethyltetramethylene diamine, 2-methyloctamethylenediamine; trimethylhexamethylenediamine, meta-xylylene diamine, and/or mixtures thereof.
  • the semi-aromatic polyamide is a homopolymer, a copolymer, a terpolymer or more advanced polymers formed from monomers containing aromatic groups.
  • One or more aromatic carboxylic acids may be terephthalate or a mixture of terephthalate with one or more other carboxylic acids, such as isophthalic acid, phthalic acid, 2-methyl terephthalic acid and naphthalic acid.
  • the one or more aromatic carboxylic acids may be mixed with one or more aliphatic dicarboxylic acids, as disclosed above.
  • an aromatic diamine such as meta-xylylene diamine (MXD) can be used to provide a semi-aromatic polyamide, an example of which is MXD6, a homopolymer comprising MXD and adipic acid.
  • MXD meta-xylylene diamine
  • Preferred polyamides disclosed herein are homopolymers or copolymers wherein the term copolymer refers to polyamides that have two or more amide and/or diamide molecular repeat units.
  • the homopolymers and copolymers are identified by their respective repeat units.
  • the repeat units are listed in decreasing order of mole % repeat units present in the copolymer. The following list exemplifies the abbreviations used to identify monomers and repeat units in the homopolymer and copolymer polyamides (PA):
  • the term “6” when used alone designates a polymer repeat unit formed from -caprolactam.
  • the “6” when used in combination with a diacid such as T, for instance 6T, the “6” refers to HMD.
  • the diamine In repeat units comprising a diamine and diacid, the diamine is designated first.
  • the first “6” refers to the diamine HMD, and the second “6” refers to adipic acid.
  • repeat units derived from other amino acids or lactams are designated as single numbers designating the number of carbon atoms.
  • Polyamides having no melting point selected from the group consisting of poly(hexamethylene isophthalamide/ hexamethylene terephthalamide) (61/6T) and poly(hexamethylene isophthalamide/hexamethylene terephthalamide/hexamethylene hexanediamide) (61/6T/66).
  • Polyamides may have semiaromatic repeat units to the extent that the melting point is less than 210° C. and generally the semiaromatic polyamides of the group have less than 40 mole percent semiaromatic repeat units.
  • Semiaromatic repeat units are defined as those derived from monomers selected from one or more of the group consisting of: aromatic dicarboxylic acids having 8 to 20 carbon atoms and aliphatic diamines having 4 to 20 carbon atoms.
  • polyamide resin is selected from Group (III) Polyamides selected from the group consisting of poly(tetramethylene hexanediamide/tetramethylene terephthalamide) (PA46/4T), poly(tetramethylene hexanediamide/hexamethylene terephthalamide) (PA46/6T), poly(tetramethylene hexanediamide/2-methylpentamethylene hexanediamide/decamethylene terephthalamide) PA46/D6/10T), poly(hexamethylene hexanediamide/hexamethylene terephthalamide) (PA66/6T), poly(hexamethylene hexanediamide/hexamethylene isophthalamide/hexamethylene terephthalamide PA66/61/6T, and poly(hexamethylene hexanediamide/2-methylpentamethylene hexanediamide/hexamethylene terephthalamide (PA46/4T), poly(tetramethylene hexanedia
  • polyamide resin is selected from Group (IV) Polyamides selected from the group consisting of poly(tetramethylene terephthalamide/hexamethylene hexanediamide) (PA4T/66), poly(tetramethylene terephthalamide/ ⁇ -caprolactam) (PA4T/6), poly(tetramethylene terephthalamide/hexamethylene dodecanediamide) (PA4T/612), poly(tetramethylene terephthalamide/2-methylpentamethylene hexanediamide/hexamethylene hexanediamide) (PA4T/D6/66), poly(hexaamethylene terephthalamide/2-methylpentamethylene terephthalamide/hexamethylene hexanediamide) (PA6T/DT/66), poly(hexamethylene terephthalamide/hexamethylene hexanediamide) PA6T/66, poly(hexamethylene terephthalamide/hexamethylene hexan
  • polyamide resin is selected from Group (V) Polyamides selected from the group consisting of poly(tetramethylene terephthalamide/2-methylpentamethylene terephthalamide) PA4T/DT, poly(tetramethylene terephthalamide/hexamethylene terephthalamide) PA4T/6T, poly(tetramethylene terephthalamide/decamethylene terephthalamide) PA4T/10T, poly(tetramethylene terephthalamide/dodecamethylene terephthalamide)PA4T/12T, poly(tetramethylene terephthalamide/2-methylpentamethylene terephthalamide/hexamethylene terephthalamide) (PA4T/DT/6T), poly(tetramethylene terephthalamide/hexamethylene terephthalamide/2-methylpentamethylene terephthalamide) (PA4T/6T/DT), poly(hexamethylene terephthalamide resin is selected from Group (V) Polyamides selected from the group consisting
  • poly(dodecamethylene terephthalamide) PA12T
  • poly(dodecamethylene terephthalamide)/tetramethylene terephthalamide) PA12T/4T
  • PA12T/6T poly(dodecamethylene terephthalamide)/decamethylene terephthalamide) (PA12T/10T)
  • PA12T/DT poly(dodecamethylene terephthalamide)/2-methylpentamethylene terephthalamide)
  • a most preferred Group (V) polyamide is PA6T/DT.
  • the polyamide is a Group (I) Polyamide, Group (II) Polyamide, Group (III) Polyamide, Group (IV) Polyamide, Group (V) Polyamide or Group (VI) Polyamide, respectively.
  • the polyamides may also be blends of two or more polyamides.
  • Preferred blends include those selected from the group consisting of Group (I) and Group (II) Polyamides; Group (I) and Group (III) Polyamide, Group (I) and Group (VI) Polyamides, Group (II) and Group (III) Polyamides, Group (II) and Group (IV) Polyamides, Group (II) and Group (V) Polyamides, Group (II) and Group (VI) Polyamides, Group (III) and Group (VI) Polyamides, and Group (IV) and Group (V) Polyamides.
  • a preferred blend includes Group (II) and Group (V) Polyamides, and a specific preferred blend includes poly(hexamethylene hexanediamide) (PA 66) and poly(hexamethylene terephthalamide/2-methylpentamethylene terephthalamide) (PA 6T/DT).
  • Another preferred blend includes Group (II) and Group (III) Polyamides and a specific preferred blend includes poly( ⁇ -caprolactam) (PA6) and poly(hexamethylene hexanediamide/hexamethylene terephthalamide (PA66/6T).
  • PA6 poly( ⁇ -caprolactam)
  • PA66/6T poly(hexamethylene hexanediamide/hexamethylene terephthalamide
  • thermoplastic article comprising a thermoplastic polyamide composition as disclosed above, wherein molded 4 mm test bars prepared from said polyamide composition, and exposed at a test temperature at 210° C. for a test period of 500 hours, in an atmosphere of air, and tested according to ISO 527-2/1A, have, on average, a retention of tensile strength of at least 50 percent, as compared with that of an unexposed control of identical composition and shape.
  • Thermoplastic polyamide compositions meeting these test requirements are referred to as “meeting the requirements of AOA 210° C./500 hours testing.”
  • thermoplastic polyamide compositions meeting the requirements of AOA 210° C./500 hours testing comprise one or more polyamide resins wherein said polyamide resin comprises a one or more polyamides independently selected from the groups consisting of Group (II) polyamides, Group (III) polyamides, Group (IV) polyarrides, Group (V) polyamides and Group (VI) polyamides, as disclosed above.
  • thermoplastic polyamide compositions meeting the requirements of AOA 210° C./500 hours are Group (II) polyamides, Group (III) Polyamides, Group (IV) Polyarnides, Group (V) Polyamides and Group (VI) Polyamides, respectively.
  • a further preferred embodiment is the molded or extruded thermoplastic article wherein said polyamide resin is selected from Group (IV) Polyamides and wherein said test temperature is at least 210° C. for a test period of at least 500 hours and said retention of tensile strength is at least 70%, and more preferably at least 80% and 90%.
  • said polyamide resin is selected from Group (IV) Polyamides and wherein said test temperature is at least 210° C. for a test period of at least 500 hours and said retention of tensile strength is at least 70%, and more preferably at least 80% and 90%.
  • a further preferred embodiment is the molded or extruded thermoplastic article wherein said polyamide resin is selected from Group (V) Polyamides and wherein said test temperature is at least 230° C. for a test period of at least 500 hours and said retention of tensile strength is at least 60%, and more preferably at least 70%, 80% and 90%.
  • said polyamide resin is selected from Group (V) Polyamides and wherein said test temperature is at least 230° C. for a test period of at least 500 hours and said retention of tensile strength is at least 60%, and more preferably at least 70%, 80% and 90%.
  • the molded or extruded thermoplastic article comprises 0.25 to 15 weight percent of one or more polyhydric alcohols having more than two hydroxyl groups and having a number average molecular weight (M n ) of less than 2000 of less than 2000 as determined for polymeric materials with gel permeation chromatography (GPC)
  • Polyhydric alcohols may be selected from aliphatic hydroxylic compounds containing more than two hydroxyl groups, aliphatic-cycloaliphatic compounds containing more than two hydroxyl groups, cycloaliphatic compounds containing more than two hydroxyl groups, aromatic and saccharides.
  • An aliphatic chain in the polyhydric alcohol can include not only carbon atoms but also one or more hetero atoms which may be selected, for example, from nitrogen, oxygen and sulphur atoms.
  • a cycloaliphatic ring present in the polyhydric alcohol can be monocyclic or part of a bicyclic or polycyclic ring system and may be carbocyclic or heterocyclic.
  • a heterocyclic ring present in the polyhydric alcohol can be monocyclic or part of a bicyclic or polycyclic ring system and may include one or more hetero atoms which may be selected, for example, from nitrogen, oxygen and sulphur atoms.
  • the one or more polyhydric alcohols may contain one or more substituents, such as ether, carboxylic acid, carboxylic acid amide or carboxylic acid ester groups.
  • polyhydric alcohol containing more than two hydroxyl groups include, without limitation, triols, such as glycerol, trimethylolpropane, 2,3-di-(2′-hydroxyethyl)-cyclohexan-1-ol, hexane-1,2,6-triol, 1,1,1-tris-(hydroxymethyl)ethane, 3-(2′-hydroxyethoxy)-propane-1,2-diol, 3-(2′-hydroxypropoxy)-propane-1,2-diol, 2-(2′-hydroxyethoxy)-hexane-1,2-diol, 6-(2′-hydroxypropoxy)-hexane-1,2-diol, 1,1,1-tris-[(2′-hydroxyethoxy)-methyl]-ethane, 1,1,1-tris-[(2′-hydroxypropoxy)-methyl]-propane, 1,1,1-tris-(4′-hydroxyphenyl)-ethane, 1,1,1,
  • Preferred polyhydric alcohols include those having a pair of hydroxyl groups which are attached to respective carbon atoms which are separated one from another by at least one atom.
  • Especially preferred polyhydric alcohols are those in which a pair of hydroxyl groups is attached to respective carbon atoms which are separated one from another by a single carbon atom.
  • the polyhydric alcohol used in the thermoplastic composition is pentaerythritol, dipentaerythritol, tripentaerythritol, di-trimethylolpropane, D-mannitol, D-sorbitol and xylitol. More preferably, the polyhydric alcohol used is dipentaerythritol and/or tripentaerythritol. A most preferred polyhydric alcohol is dipentaerythritol.
  • the content of said polyhydric alcohol in the thermoplastic composition is 0.25 to 15 weight percent, preferably 0.25 to 8 weight percent, and more preferably 0.25 to 5, and 1 to 4 weight percent.
  • the polyamide composition comprises 0.1 to 3 weight percent of one or more co-stabilizer(s) having a 10% weight loss temperature, as determined by thermogravimetric analysis (TGA), of greater than 30 degrees below the melting point of the polyamide resin, if a melting point is present, or at least 250° C. if said melting point is not present, selected from the group consisting of secondary aryl amines and hindered amine light stabilizers (HALS), and mixtures thereof.
  • TGA weight loss will be determined according to ASTM D 3850-94, using a heating rate of 10° C./min, in air purge stream, with an appropriate flow rate of 0.8 mL/second.
  • the co-stabilizer preferably has a 10% weight loss temperature, as determined by TGA, of at least 270° C., and more preferably 290° C., 320° C., and 340° C., and most preferably at least 350° C.
  • the one or more co-stabilizers preferably are present from at or about 0.1 to at or about 1 weight percent, or more preferably from at or about 0.1 to at or about 0.7 weight percent, based on the total weight of the polyamide composition.
  • Secondary aryl amines useful in the invention are high molecular weight organic compound having low volatility.
  • the high molecular weight organic compound will be selected from the group consisting of secondary aryl amines further characterized as having a molecular weight of at least 260 g/mol and preferably at least 350 g/mol, together with a 10% weight loss temperature as determined by thermogravimetric analysis (TGA) of at least 290° C., preferably at least 300° C., 320° C., 340° C., and most preferably at least 350° C.
  • TGA thermogravimetric analysis
  • secondary aryl amine an amine compound that contains two carbon radicals chemically bound to a nitrogen atom where at least one, and preferably both carbon radicals, are aromatic.
  • aromatic radicals such as, for example, a phenyl, naphthyl or heteroaromatic group, is substituted with at least one substituent, preferably containing 1 to about 20 carbon atoms.
  • suitable secondary aryl amines include 4,4′di( ⁇ , ⁇ -dimethylbenzyl)diphenylamine available commercially as Naugard 445 from Uniroyal Chemical Company, Middlebury, Conn.; the secondary aryl amine condensation product of the reaction of diphenylamine with acetone, available commercially as Aminox from Uniroyal Chemical Company; and para-(paratoluenesulfonylamido) diphenylamine also available from Uniroyal Chemical Company as Naugard SA.
  • Other suitable secondary aryl amines include N,N′-di-(2-naphthyl)-p-phenylenediamine, available from ICI Rubber Chemicals, Calcutta, India.
  • Suitable secondary aryl amines include 4,4′-bis( ⁇ , ⁇ ′-tertiaryoctyl)diphenylamine, 4,4′-bis(a-methylbenzhydryl)diphenylamine, and others from EP 0509282 B1.
  • the hindered amine light stabilizers may be one or more hindered amine type light stabilizers (HALS).
  • HALS are compounds of the following general formulas and combinations thereof:
  • R 1 up to and including R 5 are independent substituents.
  • suitable substituents are hydrogen, ether groups, ester groups, amine groups, amide groups, alkyl groups, alkenyl groups, alkynyl groups, aralkyl groups, cycloalkyl groups and aryl groups, in which the substituents in turn may contain functional groups; examples of functional groups are alcohols, ketones, anhydrides, imines, siloxanes, ethers, carboxyl groups, aldehydes, esters, amides, imides, amines, nitriles, ethers, urethanes and any combination thereof.
  • a hindered amine light stabilizer may also form part of a polymer or oligomer.
  • the HALS is a compound derived from a substituted piperidine compound, in particular any compound derived from an alkyl-substituted piperidyl, piperidinyl or piperazinone compound, and substituted alkoxypiperidinyl compounds.
  • Examples of such compounds are: 2,2,6,6-tetramethyl-4-piperidone; 2,2,6,6-tetrametyl-4-piperidinol; bis-(1,2,2,6,6-pentamethyl piperidyl)-(3′,5′-di-tert-butyl-4′-hydroxybenzyl)butylmalonate; di-(2,2,6,6-tetramethyl-4-piperidyl) sebacate (Tinuvin® 770, MW 481); oligomer of N-(2-hydroxyethyl)-2,2,6,6-tetramethyl-4-piperidinol and succinic acid (Tinuvin® 622); oligomer of cyanuric acid and N,N-di(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylene diamine; bis-(2,2,6,6-tetramethyl-4-piperidinyl) succinate; bis-(1-octyloxy-2,2,6,6-
  • Preferred HALS include high-molecular weight oligomeric or polymeric HALS having a molecular weight of more than about 1000, and preferably more than about 2000.
  • HALS are selected from the group consisting or di-(2,2,6,6-tetramethyl-4-piperidyl) sebacate (Tinuvin® 770, MW 481) Nylostab® S-EED (Clariant Huningue S.
  • a preferred embodiment comprises at least two co-stabilizers, at least one selected from the secondary aryl amines; and at least one selected from the group of HALS, as disclosed above, wherein the total weight percent of the mixture of co-stabilizers is at least 0.5 wt percent, and preferably at least 0.9 weight percent.
  • the molded or extruded thermoplastic article comprises 10 to about 60 weight percent, and preferably about 12.5 to 55 weight percent and 15 to 50 weight percent, of one or more reinforcement agents.
  • the reinforcement agent may be any filler, but is preferably selected from the group consisting calcium carbonate, glass fibers with circular and noncircular cross-section, glass flakes, glass beads, carbon fibers, talc, mica, wollastonite, calcined clay, kaolin, diatomite, magnesium sulfate, magnesium silicate, barium sulfate, titanium dioxide, sodium aluminum carbonate, barium ferrite, potassium titanate and mixtures thereof.
  • Glass fibers with noncircular cross-section refer to glass fiber having a cross section having a major axis lying perpendicular to a longitudinal direction of the glass fiber and corresponding to the longest linear distance in the cross section.
  • the non-circular cross section has a minor axis corresponding to the longest linear distance in the cross section in a direction perpendicular to the major axis.
  • the non-circular cross section of the fiber may have a variety of shapes including a cocoon-type (figure-eight) shape, a rectangular shape; an elliptical shape; a roughly triangular shape; a polygonal shape; and an oblong shape.
  • the cross section may have other shapes.
  • the ratio of the length of the major axis to that of the minor access is preferably between about 1.5:1 and about 6:1.
  • the ratio is more preferably between about 2:1 and 5:1 and yet more preferably between about 3:1 to about 4:1.
  • Suitable glass fiber are disclosed in EP 0 190 001 and EP 0 196 194.
  • the molded or extruded thermoplastic article optionally, comprises 0 to 50 weight percent of a polymeric toughener comprising a reactive functional group and/or a metal salt of a carboxylic acid.
  • the molded or extruded thermoplastic article comprises 2 to 20 weight percent polymeric toughener selected from the group consisting of: a copolymer of ethylene, glycidyl (meth)acrylate, and optionally one or more (meth)acrylate esters; an ethylene/a-olefin or ethylene/a-olefin/diene copolymer grafted with an unsaturated carboxylic anhydride; a copolymer of ethylene, 2-isocyanatoethyl (meth)acrylate, and optionally one or more (meth)acrylate esters; and a copolymer of ethylene and acrylic acid reacted with a Zn, Li, Mg or Mn compound to form the corresponding ionomer.
  • the polyamide composition may also comprise other additives commonly used in the art, such other heat stabilizers or antioxidants, antistatic agents, blowing agents, lubricants, plasticizers, and colorant and pigments.
  • heat stabilizers include copper stabilizers and hindered phenols, and mixtures thereof.
  • thermoplastic articles of the invention A significant advantage of the molded or extruded thermoplastic articles of the invention is that high thermal stability is provided without the use of conventional copper heat stabilizers. Copper heat stabilizers tend to act as corrosive agents over long periods of time at elevated temperatures; and in some environments actually cause degradation of semiaromatic polymers.
  • another embodiment is molded or extruded thermoplastic article wherein said polyamide composition comprises less than 25 ppm copper as determined with atomic absorption spectroscopy.
  • the polyamide composition is a mixture by melt-blending, in which all polymeric ingredients are adequately mixed, and all non-polymeric ingredients are adequately dispersed in a polymer matrix.
  • Any melt-blending method may be used for mixing polymeric ingredients and non-polymeric ingredients of the present invention.
  • polymeric ingredients and non-polymeric ingredients may be fed into a melt mixer, such as single screw extruder or twin screw extrjder, agitator, single screw or twin screw kneader, or Banbury mixer, and the addition step may be addition of all ingredients at once or gradual addition in batches.
  • the polyamide composition having a polyhydroxy polymer, as disclosed above, is useful in increasing long-term heat stability at high temperatures of molded or extruded articles made therefrom.
  • the long-term heat stability of the articles can be assessed by exposure (air oven ageing) of 4 mm thick test samples at various test temperatures in an oven for various test periods of time.
  • the oven test temperatures for the composition disclosed herein include 170° C. and 500 hours test periods; 210° C. and 500 hours test periods; and 230° C. and 500 hours test periods.
  • the test samples, after air oven ageing, are tested for tensile strength and elongation to break, according to ISO 527-2/1A test method; and compared with unexposed controls having identical composition and shape, that are dry as molded (DAM).
  • the comparison with the DAM controls provides the retention of tensile strength and/or retention of elongation to break, and thus the various compositions can be assessed as to long-term heat stability performance.
  • thermoplastic polyamide composition has an AOA 170° C./500 hours retention of tensile strength of at least 50% and preferably at least 60, 70, 80, and 90%, based upon comparison with DAM non-exposed controls.
  • thermoplastic polyamide composition has an AOA 210° C./500 hours retention of tensile strength of at least 50% and preferably at least 70, 80, and 90%, based upon comparison with DAM non-exposed controls.
  • the present invention relates a use of the above disclosed polyamide compositions for high temperature applications.
  • the present invention relates to a method for manufacturing an article by shaping the thermoplastic corriposition of the invention.
  • articles are films or laminates, automotive parts or engine parts or electrical/electronics parts.
  • shaping it is meant any shaping technique, such as for example extrusion, injection moulding, thermoform moulding, compression moulding or blow moulding.
  • the article is shaped by injection moulding or blow moulding.
  • the molded or extruded thermoplastic articles disclosed herein may have application in many vehicular components that meet one or more of the following requirements: high impact requirements; significant weight reduction (over conventional metals, for instance); resistance to high temperature; resistance to oil environment; resistance to chemical agents such as coolants; and noise reduction allowing more compact and integrated design.
  • Specific molded or extruded thermoplastic articles are selected from the group consisting of charge air coolers (CAC); cylinder head covers (CHC); oil pans; engine cooling systems, including thermostat and heater housings and coolant pumps; exhaust systems including mufflers and housings for catalytic converters; air intake manifolds (AIM); and timing chain belt front covers.
  • CAC charge air coolers
  • CHC cylinder head covers
  • oil pans oil pans
  • engine cooling systems including thermostat and heater housings and coolant pumps
  • exhaust systems including mufflers and housings for catalytic converters
  • AIM air intake manifolds
  • a charge air cooler is a part of the radiator of a vehicle that improves engine combustion efficiency.
  • Charge air coolers reduce the charge air temperature and increase the density of the air after compression in the turbocharger thus allowing more air to enter into the cylinders to improve engine efficiency. Since the temperature of the incoming air can be more than 200° C. when it enters the charge air cooler, it is required that this part be made out of a composition maintaining good mechanical properties under high temperatures for an extended period of time.
  • the compounded mixture was extruded in the form of laces or strands, cooled in a water bath, chopped into granules and placed into sealed aluminum lined bags in order to prevent moisture pick up.
  • the cooling and cutting conditions were adjusted to ensure that the materials were kept below 0.15 wt % of moisture level.
  • the thickness of the test specimens was 4 mm and a width of 10 mm according to ISO 527/1A at a testing speed of 5 mm/min (tensile strength and elongation). Tensile Modulus was measured at 1 mm/min.
  • test specimens were heat aged in a re-circulating air ovens (Heraeus type UT6060) according to the procedure detailed in ISO 2578. At various heat aging times, the test specimens were removed from the oven, allowed to cool to room temperature and sealed into aluminum lined bags until ready for testing. The tensile mechanical properties were then measured according to ISO 527 using a Zwick tensile instrument. The average values obtained from 5 specimens are given in the Tables.
  • Retention of tensile strength (TS) and elongation at break (EL) corresponds to the percentage of the tensile strength and elongation at break after heat aging for 500 hours 1000 hours in comparison with the value of specimens non-heat-aged control specimens considered as being 100%.
  • PA 6T/66 refers HTN502 NC010, a copolyamide made from terephthalic acid, adipic acid, and hexamethylenediamine; wherein the two acids are used in a 55:45 molar ratio; having a melting point of ca. 310° C., having an inherent viscosity (IV), according to ASTM D2857 method, in the range of 0.9 to 1.0 (typically 0.96) available from E.I. DuPont de Nemours and Company, Wilmington, Del., USA.
  • PA6T/DT refers HTN501 NC010, a copolyamide of terephthalic acid, hexamethylenediamine, and 2-methyl-pentamethylenediamine having an inherent viscosity (IV), according to ASTM D2857 method, in the range of 0.8 to 0.95 (typically 0.88) and a melting point of about 300° C., and available from E.I. DuPont de Nemours and Company, Wilmington, Del., USA.
  • IV inherent viscosity
  • DPE refers to dipentaerythritol that was from Perstorp Speciality Chemicals AB, Perstorp, Sweden as Di-Penta 93.
  • TPE refers to tripentaerythritol that was from Sigma Aldrich Co., Milwaukee Wis.
  • Glass Fiber D refers to PPG 3540 chopped glass fiber available fro PPG Industries, Pittsburgh, Pa.
  • Naugard® 445 hindered amine refers to 4,4′di(. ⁇ , ⁇ -dimethylbenzyl)diphenylamine available commercially from Uniroyal Chemical Company, Middlebury, Conn.
  • Irganox® 1010 stabilizer was available from Ciba Speciality Chemicals Inc, Switzerland.
  • Irganox® 1098 stabilizer was available from Ciba Speciality Chemicals Inc, Switzerland.
  • Chimassorb® 944 refers to (poly[[6-[(1,1,3,3-tetramethylbutyl) amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)-imino]-1,6-hexanediyl [(2,2,6,6-tetramethyl-4-piperidinyl)imino]]), supplied by Ciba Specialty Chemicals.
  • Chimassorb® 119 is (1,3,5-triazine-2,4,6-triamine, N,N′′′-[1,2-ethanediylbis[[[4,6-bis[butyl(1,2,2,6,6-pentamethyl-4-piperidinyl)amino]-1,3,5-triazine-2-yl]imino]-3,1-propanediyl]]-bis[N′, N′′-dibutyl-N′,N′′-bis(1,2,2,6,6-pentamethyl-4-piperidinyl)), supplied by Ciba Specialty Chemicals.
  • Wax OP is a lubricant manufactured by Clariant Corp., Charlotte, N.C.
  • Black Pigment B refers to 25 wt % carbon black in PA6 polymer.
  • compositions of Examples 1 and Comparative Examples C-1-C-5 are listed in Table 1 for PA6T/DT compositions.
  • Tensile properties after AOA at 210° C/ and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 1. Higher values of tensile strength (TS) mean better mechanical properties. Higher % retention of tensile strength indicate a higher thermal stability.
  • Example 1 having 1.5 wt % DPE and 1 wt % Naugard® 445 hindered amine has higher % retention of tensile strength than the Comparative Examples containing Naugard alone; copper heat stabilizer alone; 1.5 wt % DPE alone; or Naugard® 445 hindered amine alone.
  • Example 1 shows surprising and unexpected results, indicated by the much higher % retention of tensile strength under AOA at 230° C./1000 hours, as compared to conventional copper stabilizer commonly used in commercial products.
  • compositions of Examples 2 and Comparative Examples C-6-C-10 are listed in Table 2 for PA6T/DT compositions.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 2
  • compositions of Examples 3 and Comparative Examples C-11-C-14 are listed in Table 3 for PA6T/66 compositions.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 3
  • Example 3 having 2 wt % DPE and 0.5 wt % Naijgard® 445 hindered amine has higher % retention of tensile strength than the Comparative Examples containing 2.0 wt % DPE alone; Naugard® 445 hindered amine alone; or a combination of Naugard® 445 hindered amine and Irganox® 1098 hindered phenol.
  • compositions of Examples 4-7 are listed in Table 4 for PA6T/66 compositions with various co-stabilizers in combination with 2 wt % TPE.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 4. Examples 4-7 all show unexpectedly high retention of tensile strength under AOA 230° C./1000 hour ageing as compared with C-11 having a conventional copper heat stabilizer.
  • compositions of Examples 8-10 are listed in Table 5 for PA6T/66 compositions with various co-stabilizers in combination with 2 wt % TPE.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 5.
  • compositions of Examples 11-13 are listed in Table 6 for PA6T/66 compositions with various co-stabilizers in combination with 3 wt % DPE.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 5.
  • Examples 11-13 all show unexpected and surprising retention of tensile strength under AOA 230° C./1000hour ageing as compared with C-15 having a conventional copper heat stabilizer.
  • Example 11 12 13 C-15 PA6T/66 61.25 60.75 60.75 64.35 Chimassorb ® 944FD 0.50 DPE 3.00 3.00 3.00 Chimassorb ® 119FL 0.50 Naugard ® 445 0.50 0.50 0.50 Wax OP 0.25 0.25 0.25 0.25 Cu heat stabilizer 0.40 Glass Fiber D 35.00 35.00 35.00 AOA 210° C.
  • Comparative Examples C-16- C-20 are listed in Table 7 for PA6T/66 compositions with various co-stabilizers, but without a polyhydric alcohol.
  • Tensile properties after AOA at 210° C. and 230° C. at 500 h and 1000 h, and retention of physical properties are listed in Table 7.
  • the various combinations of co-stabilizers fail to provide high retention of tensile strength under AOA at 230 C/1000 hours, as compared to the Examples 4-13.
  • Examples 4-13 having a combination of polyhydric alcohol and co-stabilizer, show retention of tensile strength of at least 77% in all examples at AOA of 230 C/1000 hours; whereas the comparative examples, show a maximum of only 44% under the same conditions.

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US9284443B2 (en) 2011-06-21 2016-03-15 E. I. Du Pont De Nemours And Company Heat-stabilized acrylate elastomer composition and process for its production
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