# US 11,993,061 B2 · Multilayer composite material containing special polycarbonate compositions as a matrix material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,993,061 B2 - Document ID: US11993061B2 - Status: Granted - Kind: B2 - Application number: 17/538,218 - Filed: 2021-11-30 - Published: 2022-03-24 - Granted: 2024-05-28 - Earliest claimed: 2016-07-04 - Assignees: Covestro Deutschland AG - Applicants: Covestro Deutschland AG - Inventors: Rolf Wehrmann; Anke Boumans; Helmut Werner Heuer; Thomas Grimm; Matthias Knaupp; John Bauer - Web page: https://patentgrep.com/patent/US11993061B2 ## CPC - B32B 27/12: next to a fibrous or filamentary layer - B05D 3/0218: {Pretreatment, e.g. heating the substrate} - B29C 65/02: by heating, with or without pressure - B29C 65/44: Joining a heated non plastics element to a plastics element - B32B 5/024: {Woven fabric} - B32B 5/026: {Knitted fabric} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 21/08: of synthetic resin - B32B 21/10: Next to a fibrous or filamentary layer - B32B 27/08: of synthetic resin - B32B 27/18: characterised by the use of special additives - B32B 27/20: using fillers, pigments, thixotroping agents - B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42} - B32B 27/281: {comprising polyimides} - B32B 27/285: {comprising polyethers} - B32B 27/288: {comprising polyketones} - B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers} - B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF} - B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers} - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B32B 27/34: comprising polyamides - B32B 27/36: comprising polyesters - B32B 27/365: {comprising polycarbonates} - B32B 27/40: comprising polyurethanes - B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines - C08J 5/04: Reinforcing macromolecular compounds with loose or coherent fibrous material - C08J 5/10: characterised by the additives used in the polymer mixture - C08K 3/34: Silicon-containing compounds - C08K 5/0066: {Flame-proofing or flame-retarding additives} - C08K 5/52: Phosphorus bound to oxygen only - C08K 5/521: Esters of phosphoric acids, e.g. of H3PO4 - C08K 5/5399: Phosphorus bound to nitrogen - C08K 7/04: inorganic - C08L 69/00: Compositions of polycarbonates; Compositions of derivatives of polycarbonates - B29C 65/022: {Particular heating or welding methods not otherwise provided for} - B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)} - B32B 37/06: characterised by the heating method - B32B 2038/0072: {Orienting fibers} - B32B 2260/023: Two or more layers - B32B 2260/046: Synthetic resin - B32B 2262/02: Synthetic macromolecular fibres - B32B 2262/0261: Polyamide fibres - B32B 2262/0269: Aromatic polyamide fibres - B32B 2262/0276: Polyester fibres - B32B 2262/10: Inorganic fibres - B32B 2262/101: Glass fibres - B32B 2262/103: Metal fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2307/558: Impact strength, toughness - B32B 2307/71: Resistive to light or to UV - B32B 2307/732: Dimensional properties - B32B 2307/738: Thermoformability - B32B 2457/00: Electrical equipment - C08J 2369/00: Characterised by the use of polycarbonates; Derivatives of polycarbonates - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) ## 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. ## Claims ### Claim 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 C1- to C8-alkyl radical, C1- to C8-alkoxy radical, in each case optionally alkyl- and/or halogen-substituted C5- to C6-cycloalkyl radical, in each case optionally alkyl- and/or halogen- and/or hydroxyl-substituted C6- to C20-aryloxy radical, in each case optionally alkyl- and/or halogen-substituted C7- to C12-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 R1, R2, R3 and R4 are each independently a C1- to C8-alkyl radical, in each case optionally halogenated and in each case branched or unbranched, and/or C5- to C6-cycloalkyl radical, C6- to C20-aryl radical or C7- to C12-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. ### Claim 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 C1- to C8-alkyl radical, C1- to C8-alkoxy radical, in each case optionally alkyl- and/or halogen-substituted C5- to C6-cycloalkyl radical, in each case optionally alkyl- and/or halogen- and/or hydroxyl-substituted C6- to C20-aryloxy radical, in each case optionally alkyl- and/or halogen-substituted C7- to C12-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 R1, R2, R3 and R4 are each independently a C1- to C8-alkyl radical, in each case optionally halogenated and in each case branched or unbranched, and/or C5- to C6-cycloalkyl radical, C6- to C20-aryl radical or C7- to C12-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. ### Claim 3 (depends on 1) The process according to claim 1, wherein the composition is applied to the raw fibre tape under pressure-shear vibration. ### Claim 4 (depends on 1) 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. ### Claim 5 (depends on 1) The process according to claim 1, wherein the fibre material are endless fibres and the endless fibres are aligned unidirectionally. ### Claim 6 (depends on 1) 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. ### Claim 7 (depends on 2) 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. ### Claim 8 (depends on 2) 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. ### Claim 9 (depends on 2) 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° . ### Claim 10 (depends on 2) 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. ### Claim 11 (depends on 1) The process according to claim 1, wherein the molten, aromatic polycarbonate-based composition further comprises further additives.