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US 2026/0242596 A1Published application
Method for producing a composite component with a support comprising polycarbonate of a specific oh content
AssigneeCovestro Deutschland AG
InventorsBenjamin Herzberg, Michael Delbeck, Alexander Meyer, Thomas Grimm, Christoph Klinkenberg, Ruediger Hahn
Life of this patent
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Abstract
The present invention relates to a method for producing composite components with improved interlaminar bonding, the components comprising a carrier, comprising polycarbonate and at least one polyurethane layer that is in direct contact with this carrier. The invention also relates to composite components with improved interlaminar bonding, and to the use of a polycarbonate with defined OH content as a carrier material in the production of composite components with improved interlaminar bonding.
Claims21
1:
- A process for producing a composite component part comprising
- a) a carrier composed of a thermoplastic composition and
- b) at least one polyurethane layer in direct contact with the carrier,
- comprising the steps of
- (i) (ia) injecting a melt of a thermoplastic composition (Z) into a mold cavity followed by cooling to form the carrier or
- (ib) introducing a film comprising an outer ply composed of a thermoplastic composition (Z) into a mold cavity, overmolding this film with a melt of a further thermoplastic composition (Z2) on the side facing away from the outer ply of the film followed by cooling to form the carrier,
- wherein the thermoplastic composition (Z) contains
- A) at least 95.0% by weight of an aromatic polycarbonate having a phenolic OH content of 230 ppm to 1500 ppm and
- B) greater than 0% to 5.0% by weight of at least one polymer additive selected from the group consisting of flame retardants, flame retardant synergists, smoke-inhibiting additives, anti-drip agents, internal and external lubricants and demolding agents, flowability aids, antistats, conductivity additives, nucleating agents, stabilizers, antibacterial additives, IR absorbers, optical brighteners, fluorescent additives, fillers and reinforcers, dyes and pigments and Bronsted-acidic compounds, and
- wherein the further thermoplastic composition (Z2) may be the same as or different from the thermoplastic composition (Z),
- (ii) enlarging the cavity of the mold and thus producing a gap or introducing the carrier into a second cavity of the mold which is larger than the first cavity in terms of its hollow mold dimensions, thus producing a gap, and wherein in case (ib) the carrier is oriented such that the outer ply of the film composed of the thermoplastic composition (Z) faces the gap,
- (iii) injecting a reactive polyurethane raw material mixture containing
- at least one polyisocyanate component,
- at least one polyfunctional H-active compound and
- optionally at least one polyurethane additive and/or processing auxiliary,
- into the gap between the carrier and the mold surface, wherein the polyurethane raw material mixture undergoes polymerization to afford a compact polyurethane layer or to afford a polyurethane foam layer in contact with the surface of the carrier,
- (iv) demolding the composite component part from the mold cavity.
14 more elements
2:
- The process as claimed in claim 1, characterized in that the aromatic polycarbonate of component A) has a phenolic OH content of 310 ppm to 1100 ppm.
3:
- The process as claimed in claim 1, characterized in that the aromatic polycarbonate of component A) comprises one of the following structures (4) to (7):
- in which the phenyl rings may independently be mono- or disubstituted with C1- to C8-alkyl, halogen, preferably C1- to C4-alkyl, particularly preferably with methyl, and X represents a single bond, a linear or branched C1- to C6-alkylene group, a C2- to C10-alkylidene group or a C5- to C10-cycloalkylidene group, preferably represents a single bond or C1- to C4-alkylene and especially preferably isopropylidene and the “- - -” represent the bonding of the structures (4) to (7) into the aromatic polycarbonate.
4:
- The process as claimed in claim 3, characterized in that the amount of structural units (4) to (7) sums to 50 ppm to 1000 ppm.
5:
- The process as claimed in claim 1, characterized in that at least at one point the carrier has a wall thickness of 0.5 mm to 10 mm.
6:
- The process as claimed in claim 1, characterized in that the polyurethane layer has a layer thickness of 1 μm to 20 cm.
7:
- The process as claimed in claim 1, characterized in that the thermoplastic composition (Z) is composed of components A) and B).
8:
- The process as claimed in claim 1, characterized in that component B) is selected from the group consisting of least one of flame retardants, flame retardant synergists, smoke-inhibiting additives, anti-drip agents, internal and external lubricants and demolding agents, flowability aids, antistats, conductivity additives, nucleating agents, stabilizers, antibacterial additives, scratch resistance-improving additives, IR absorbers, optical brighteners, fluorescent additives, fillers and reinforcers, dyes and pigments and Bronsted-acidic compounds.
9:
- The process as claimed in claim 1, characterized in that a low-solvent reactive polyurethane raw material mixture having a solvent content of at most 10% by weight, based on the polyurethane raw material mixture.
10:
- The process as claimed in claim 1, characterized in that a solvent-free reactive polyurethane raw material mixture is used.
11:
- The process as claimed in claim 1, characterized in that the reactive polyurethane raw material mixture has a pot life of at most 1 min.
12:
- The process as claimed in claim 1, characterized in that the polymerization in process step (iii) is carried out under elevated pressure.
13:
- A composite component part comprising
- a) a carrier composed of a thermoplastic composition (Z) containing
- A) at least 95.0% by weight of an aromatic polycarbonate having a phenolic OH content of 230 ppm to 1500 ppm and
- B) 0% to 5.0% by weight of at least one commercially available polymer additive,
- b) at least one polyurethane layer in direct contact with the carrier, produced by the process as claimed in claim 1.
2 more elements
14:
- The composite component part as claimed in claim 13, characterized in that it is an interior or exterior component part of a rail vehicle, aircraft or motor vehicle.
(canceled)
16:
- The process as claimed in claim 1, characterized in that the aromatic polycarbonate of component A) comprises two of the following structures (4) to (7):
- in which the phenyl rings may independently be mono- or disubstituted with C1- to C8-alkyl, halogen, preferably C1- to C4-alkyl, particularly preferably with methyl, and X represents a single bond, a linear or branched C1- to C6-alkylene group, a C2- to C10-alkylidene group or a C5- to C10-cycloalkylidene group, preferably represents a single bond or C1- to C4-alkylene and especially preferably isopropylidene and the “- - -” represent the bonding of the structures (4) to (7) into the aromatic polycarbonate.
17:
- The process as claimed in claim 1, characterized in that a low-solvent reactive polyurethane raw material mixture having a solvent content of at most 2% by weight, based on the polyurethane raw material mixture.
18:
- The process as claimed in claim 1, characterized in that a low-solvent reactive polyurethane raw material mixture having a solvent content of at most 1% by weight, based on the polyurethane raw material mixture.
19:
- The process as claimed in claim 1, characterized in that the reactive polyurethane raw material mixture has a pot life of at most 30 s.
20:
- The process as claimed in claim 1, characterized in that the reactive polyurethane raw material mixture has a pot life of at most 10 s.
21:
- The process as claimed in claim 1, wherein component B) is present in the thermoplastic composition (Z) from 0.05% by weight to 4.0% by weight.
Dependencies are inferred from the claim text.