Molded body and process for producing the same

A fibre-reinforced composite (K) comprising:

• (A) ≥50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one continuous fibrous reinforcement material;
• (B)<50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100° C. and a melt volume-flow rate (MVR (220/10) according to ISO 1133) of 10 to 90 mL/10 min, wherein the at least one matrix polymer composition (B) comprises:
• (B1) 60 to 80 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α-methyl styrene and acrylonitrile having a number average molecular weight Mn of 30,000 to 100,000 g/mol;
• and
• (B2) 20 to 40 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene, acrylonitrile, maleic acid anhydride, and/or maleic acid and optionally monomers comprising further chemical functional groups which are appropriate to interact with the surface of the at least one continuous fibrous reinforcement material (A) having a number average molecular weight Mn of 30,000 to 100,000 g/mol;
• and
• (C) optional additives;
• wherein the fibre-reinforced composite (K) is used as a starting material in a thermoforming process for the preparation of a molded body (M).

A process for thermoforming a fibre-reinforced composite (K) to a molded body (M) wherein the process comprises at least the following steps:

• (i) providing a fibre-reinforced composite (K) comprising
• (A) ≥50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one continuous fibrous reinforcement material;
• (B)<50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100° C. and a melt volume-flow rate (MVR (220/10) according to ISO 1133) of 10 to 90 mL/10 min, wherein the at least one matrix polymer composition (B) comprises:
• (B1) 60 to 80 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α-methyl styrene and acrylonitrile having a number average molecular weight Mn of 30,000 to 100,000 g/mol;
• and
• (B2) 20 to 40 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene, acrylonitrile, maleic anhydride, and/or maleic acid and optionally monomers comprising further chemical functional groups which are appropriate to interact with the surface of the at least one continuous fibrous reinforcement material (A) having a number average molecular weight Mn of 30,000 to 100,000 g/mol;
• and
• (C) optional additives;
• (ii) heating the fibre-reinforced composite (K) to a temperature (T3) at which the at least one substantially amorphous matrix polymer composition (B) is substantially softened;
• (iii) thermoforming the fibre-reinforced composition (K) in a mold at a mold surface temperature (T4) in order to obtain a molded body (M);
• and
• (iv) releasing the molded body (M) from the mold;
• wherein the mold surface temperature (T4) is 50° C.