阅读说明：本技术 成型体及其制备方法 (Molded body and method for producing same ) 是由 P·戴特迈格 E·杨克 T·舒尔茨 P·胡安 N·尼斯内 M·布林兹洛 于 2018-09-26 设计创作，主要内容包括：本发明涉及纤维增强复合材料(K)在热成型方法中的用途。此外,公开了一种将纤维增强复合材料(K)热成型为成型体(M)的方法,该方法包括至少以下步骤：(i)提供本文所述的纤维增强复合材料(K)；(ii)将纤维增强复合材料(K)加热至温度(T3),在该温度下至少一种基本上无定形的基质聚合物组合物(B)基本上被软化；(iii)在模具中在模具表面温度(T4)下将纤维增强组合物(K)热成型以获得成型体(M)；(iv)将所述成型体(M)从模具中脱模；其中所述模具表面温度(T4)≥50℃。(The invention relates to the use of a fibre-reinforced composite material (K) in a thermoforming process. Furthermore, a method for thermoforming a fiber-reinforced composite material (K) into a shaped body (M) is disclosed, comprising at least the following steps: (i) providing a fiber-reinforced composite (K) as described herein; (ii) heating the fiber-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 fiber-reinforced composition (K) in a mold at a mold surface temperature (T4) to obtain a shaped body (M); (iv) demoulding the moulded body (M) from a mould; wherein the mold surface temperature (T4) is equal to or greater than 50 ℃.)

1. Use of a fiber-reinforced composite (K) as a starting material in a thermoforming process for producing a shaped body (M), the fiber-reinforced composite (K) comprising:

(A) at least 50 wt. -% of at least one continuous fiber reinforcement, based on the total weight of the fiber-reinforced composite (K);

(B) <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100 ℃ and a melt volume flow rate (MVR (220/10) according to ISO 1133) of 10 to 90m L/10min, preferably 30 to 80m L/10min, more preferably 40 to 70m L/10min, wherein the at least one matrix polymer composition (B) comprises:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol; and

(C) optionally an additive.

2. A method of thermoforming a fibre-reinforced composite (K) into a shaped body (M), wherein the method comprises at least the following steps:

(i) providing a fiber-reinforced composite (K) comprising

(A) At least 50 wt. -% of at least one continuous fiber reinforcement, based on the total weight of the fiber-reinforced composite (K);

(B) <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100 ℃ and a melt volume flow rate (MVR (220/10) according to ISO 1133) of 10 to 90m L/10min, preferably 30 to 80m L/10min, more preferably 40 to 70m L/10min, wherein the at least one matrix polymer composition (B) comprises:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol; and

(C) optionally, an additive;

(ii) heating the fiber-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 fiber-reinforced composition (K) in a mold at a mold surface temperature (T4) to obtain a shaped body (M);

(iv) demoulding the moulded body (M) from a mould;

wherein the mold surface temperature (T4) is equal to or greater than 50 ℃.

3. The process according to claim 2, wherein the temperature (T3) is below the decomposition temperature of the at least one substantially amorphous matrix polymer composition (B), preferably below 300 ℃.

4. The method according to claim 2 or 3, wherein the temperature (T3) is in the range of ≥ 200 ℃ and ≤ 280 ℃, in particular in the range of ≥ 220 ℃ and ≤ 250 ℃.

5. The method according to any one of claims 2 to 4, wherein the mold surface temperature (T4) is lower than the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably in the range of ≥ 50 ℃ and ≤ 90 ℃, preferably in the range of ≥ 60 ℃ and ≤ 80 ℃.

6. The process according to any one of claims 2 to 4, wherein the mold surface temperature (T4) is higher than or equal to the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably higher than the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) by 10 to 50 ℃, in particular 20 to 40 ℃.

7. The method according to claim 6, wherein the method comprises the method steps of:

(i) providing a fibre-reinforced composite material (K);

(ii) heating the fiber-reinforced composite (K) to a temperature (T3) at which the at least one substantially amorphous matrix polymer composition (B) is substantially softened;

(iii) (a) thermoforming the fiber reinforced composition (K) in a mold at a first mold surface temperature (T4) to obtain a shaped body (M);

(b) reducing the temperature of the mold surface to a second mold surface temperature (T5) to cure at least the surface of the shaped body (M), the second mold surface temperature (T5) being below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B);

(iv) demoulding the moulded body (M) from a mould;

wherein the first mold surface temperature (T4) is at least 10 to 50 ℃, particularly at least 20 to 40 ℃, higher than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B) and the second mold surface temperature (T5) is at least 5 ℃, particularly at least 15 ℃, lower than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B).

8. The method according to claim 7, wherein the mold surface temperature (T4) is in the range of ≥ 130 ℃ and ≤ 210 ℃, preferably in the range of ≥ 140 ℃ and ≤ 200 ℃.

9. The method according to any one of claims 2 to 8, wherein the at least one substantially amorphous matrix polymer composition (B) has a glass transition temperature (Tg) in the range of ≥ 100 ℃ and ≤ 150 ℃.

10. The method according to any one of claims 2 to 9, wherein the method further comprises a method step, wherein preferably before the thermoforming step (iii) a film, in particular a decorative film, is applied onto at least one surface of the fiber-reinforced composite (K).

11. The method according to any one of claims 2 to 10, wherein the method further comprises a method step in which the shaped body (M) is further processed by applying a coating and/or printing on at least one surface of the shaped body (M).

12. The process according to any one of claims 2 to 9, wherein the shaped body (M) is a shaped body (M) having the appearance of carbon fibers, and wherein no post-treatment is required.

13. The process according to any one of claims 2 to 12, wherein the thermoforming process of the shaped body (M) is carried out directly after the process of preparing the fiber-reinforced composite (K), in particular before the fiber-reinforced composite (K) reaches a temperature below or equal to the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B).

14. Shaped body (M), optionally with the appearance of carbon fibres, obtained by the thermoforming process according to any of claims 2 to 13.

15. Use of a shaped body (M) according to claim 14, obtained in a process according to any one of claims 2 to 13, as an element for structural and/or aesthetic applications.

Disclosure of Invention

The fiber-reinforced composite material is composed of a plurality of reinforcing fibers embedded in a polymer matrix. The field of application of composite materials is diverse. For example, fiber reinforced composites are used in the automotive and aerospace industries. Here, the fibre-reinforced composite material prevents cracking or other disintegration of the matrix, thereby reducing the risk of accidents caused by dispersed component pieces. Many fiber-reinforced composites are capable of absorbing high forces under load before the material fails completely. At the same time, fiber-reinforced composites are distinguished by high strength, high stiffness, combined with low density and other advantageous properties, such as good ageing and corrosion resistance, compared to conventional non-reinforced materials.

The strength and rigidity of the fibre-reinforced composite material can be adapted to the direction and type of load. Here, firstly, the fibers are responsible for the strength and rigidity of the fiber-reinforced composite material. In addition, the arrangement of the fibers determines the mechanical properties of the fiber-reinforced composite. In contrast, the matrix serves primarily to introduce the majority of the forces to be absorbed into the individual fibers and to maintain the spatial arrangement of the fibers in a desired direction. Since both the fiber and the matrix material can vary, various combinations of fibers and matrix materials are possible.

In the preparation of fiber-reinforced composites, a well-balanced combination of fibers and matrix plays a crucial role. Also, the embedding strength of the fibers in the polymer matrix (fiber-matrix bonding) can have a significant impact on the performance of the fiber-reinforced composite.

The reinforcing fibers are periodically pretreated in order to optimize the fiber-matrix adhesion and compensate for the "low chemical similarity" between the fiber surface and the surrounding polymer matrix. For this purpose, so-called sizing agents (sizing agents) are added regularly. Such sizing agents are typically applied to the fibers during the manufacturing process to improve the processability of the fibers (e.g., weaving, sewing). If the sizing agent is not advantageous for subsequent further processing, it must be removed in a further processing step, such as an incineration step. In some cases, the fibers are also processed without sizing.

To manufacture the fibre-reinforced composite material, additional binders are generally applied in additional processing steps. The sizing and/or binder forms a layer on the surface of the fibers that substantially determines the interaction of the fibers with the environment. A wide variety of adhesives are available today. The skilled person will be able to select a suitable binder for use in combination with the matrix fibers and compatible polymer matrix, and also in combination with the fibers, depending on the field of application.

Fiber reinforced composites comprising a thermoplastic matrix polymer can generally be formed in a thermoforming process. The process generally includes the step of raising the temperature of the composite to a temperature at which the matrix polymer softens sufficiently to allow the composite to be shaped. This step is usually accompanied by partial decomposition of the matrix material. If a higher temperature is chosen, either release of gaseous material from the matrix material (especially water and low molecular additives, such as release agents) or substantial dripping of matrix material from the composite material may occur, due to the too low viscosity of the matrix polymer at a given temperature. The softened composite material is then typically transferred to a mold and formed into a desired shape. However, the temperature range over which this thermoforming is carried out is generally small for conventional matrix polymers. For example, for polyamide 6 as the matrix polymer, the temperature range for the thermoforming process is typically about 220 to 290 ℃. Below this temperature range curing will occur, whereas above this temperature range polymer decomposition will occur. The required temperature is therefore higher and varies only within a narrow temperature range.

Shaped bodies having the appearance of carbon fibers are known in the art and are commonly used as trim parts in visible applications. Such shaped bodies usually comprise a support structure and can be produced by different methods. In the resin transfer moulding process, a carbon fibre fabric is applied and adjusted to the surface of the (thermoplastic) support structure. The structure is then submerged with polyurethane or polyepoxy and cured for about 10 to 20 minutes, then shaped, polished, and varnished to obtain a sufficiently smooth surface. In an alternative method, carbon fiber prepregs (carbon fiber fabrics pre-impregnated with polyurethane or polyepoxy) are cured in a forming apparatus for about 10 to 20 minutes and then formed and bonded to the surface of a (thermoplastic) support structure. Usually, the final varnish is also applied to obtain a sufficiently smooth surface. Molded bodies having a high-quality surface and a high fiber volume content can be obtained from carbon fiber prepregs which are cured in an autoclave under vacuum with simultaneous application of pressure. The curing time may be as long as 20 hours. Also here, final treatment (polishing, varnishing) is usually required. All of these processes require many process steps and are very time consuming. Known fiber-reinforced moulded bodies from thermoplastic matrix materials often exhibit uneven, wavy surfaces which are unsuitable for carbon fiber appearance applications without further laborious and time-consuming processing steps, such as polishing and varnishing. Thus, fiber-reinforced moldings made of thermoplastic matrix materials have hitherto not been used for carbon fiber appearance applications.

Accordingly, there is a need for a fiber-reinforced composite material: which allows thermoforming of the composite material over a wide temperature range and preferably at low temperatures. Preferably, the process should be accompanied by little loss of material due to decomposition, degassing and/or dripping. Furthermore, it should be possible to produce shaped bodies with a high-quality surface without further processing steps and thus also for carbon fiber appearance applications. Furthermore, there is a need for an economical and environmentally friendly production.

WO 2016/170104 relates to a composite material comprising a)30 to 95 wt.% of a thermoplastic material, b)5 to 70 wt.% of reinforcing fibers; and c)0 to 40 wt.% of further additives. Thermoplastic materials mentionedThe material has a length of 10 to 70cm³MVR at 10min (220/10). The composite material may be thermoformed into a shaped body.

The inventors have surprisingly found that the use of a fiber-reinforced composite (K) as described below as starting material in a thermoforming process to obtain a shaped body (M) provides a unique combination of properties which overcomes the problems indicated above.

The first aspect of the invention relates to the use of a fiber-reinforced composite material (K) as a starting material in a thermoforming process for producing a shaped body (M), the fiber-reinforced composite material (K) comprising:

(A) at least 50 wt. -% of at least one continuous fiber reinforcement, based on the total weight of the fiber-reinforced composite (K);

(B) <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100 ℃ and a melt volume flow rate (MVR (220/10) according to ISO 1133) of 10 to 90m L/10min, preferably 30 to 80m L/10min, more preferably 40 to 70m L/10min, wherein the at least one matrix polymer composition (B) comprises:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol; and

(C) optionally an additive.

The inventors have found that a specific combination of specific features of a substantial amount of at least one continuous fibrous reinforcement (a) and the at least one substantially amorphous matrix polymer composition (B) results in a fiber-reinforced composite (K) which can be thermoformed into a shaped body (M) at a relatively low temperature and in a wide temperature range. The molded bodies (M) have a particularly smooth surface without additional treatment steps, such as coating steps. In addition, no decomposition, degassing and/or dripping is generally observed during thermoforming.

In another aspect, the invention relates to a method for thermoforming a fiber-reinforced composite material (K) into a shaped body (M), wherein the method comprises at least the following steps:

(i) providing a fiber-reinforced composite (K) comprising

(A) At least 50 wt. -% of at least one continuous fiber reinforcement, based on the total weight of the fiber-reinforced composite (K);

(B) <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of at least one substantially amorphous matrix polymer composition having a glass transition temperature (Tg) of at least 100 ℃ and a melt volume flow rate (MVR (220/10) according to ISO 1133) of 10 to 90m L/10min, preferably 30 to 80m L/10min, more preferably 40 to 70m L/10min, wherein the at least one matrix polymer composition comprises:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol; and

(C) optionally, an additive;

(ii) heating the fiber-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 fiber-reinforced composition (K) in a mold at a mold surface temperature (T4) to obtain a shaped body (M);

(iv) demoulding the moulded body (M) from a mould;

wherein the mold surface temperature (T4) is equal to or greater than 50 ℃.

In a preferred embodiment of the present invention, said process is carried out wherein said temperature (T3) is below the decomposition temperature of said at least one substantially amorphous matrix polymer composition (B), preferably below 300 ℃. In another preferred embodiment, the temperature (T3) is in the range ≥ 200 ℃ and ≤ 280 ℃, in particular in the range ≥ 220 ℃ and ≤ 250 ℃.

In another embodiment of the present invention, the process is carried out wherein the mold surface temperature (T4) is lower than the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably in the range of ≥ 50 ℃ and ≤ 90 ℃, preferably in the range of ≥ 60 ℃ and ≤ 80 ℃.

In an alternative embodiment of the invention, the process is carried out wherein the mold surface temperature (T4) is 10 to 50 ℃, in particular 20 to 40 ℃ above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B).

In a preferred embodiment, this is achieved by a process comprising the following process steps:

(i) providing a fiber-reinforced composite (K) as described herein;

(ii) heating the fiber-reinforced composite (K) to a temperature (T3) at which the at least one substantially amorphous matrix polymer composition (B) is substantially softened;

(iii) (a) thermoforming the fiber reinforced composition (K) in a mold at a first mold surface temperature (T4) to obtain a shaped body (M);

(b) reducing the temperature of the mold surface to a second mold surface temperature (T5) to cure at least the surface of the shaped body (M), the second mold surface temperature (T5) being below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B);

(iv) demoulding the moulded body (M) from a mould;

wherein the first mold surface temperature (T4) is at least 10 to 50 ℃, particularly at least 20 to 40 ℃, higher than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B) and the second mold surface temperature (T5) is at least 5 ℃, particularly at least 15 ℃, lower than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B).

The matrix polymer composition (B) preferably has a glass transition temperature (Tg) of ≥ 100 deg.C, and preferably in the range of ≥ 100 deg.C to ≤ 150 deg.C.

In one embodiment of the invention, the mold surface temperature (T4) is in the range of 130 ℃ or more and 210 ℃ or less, preferably 140 ℃ or more and 200 ℃ or less. In another preferred embodiment, the mold surface temperature (T4) is in the range of 140 ℃ to 170 ℃, preferably in the range of 140 to 160 ℃.

In a preferred embodiment of the present invention, the matrix polymer composition (B) has a mold shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range of 0.1 to 0.9%, in particular in the range of 0.2 to 0.8%. This allows the preparation of:

in one aspect of the invention, the process is conducted as a variable mold temperature process. This allows precise control of the surface temperature of the shaped body (M) and contributes to improved surface smoothness.

In another aspect of the invention, the method further comprises a method step, wherein preferably before the thermoforming step (iii), a film, in particular a decorative film, is applied onto at least one surface of the fiber-reinforced composite material (K). The high surface quality of the shaped bodies (M) prepared according to the invention allows the use of decorative films in moulds having high surface quality, i.e. good adhesion and high surface smoothness.

In a further aspect of the invention, the method further comprises a method step, wherein the shaped body (M) is further processed by applying a coating and/or printing on at least one surface of the shaped body (M). The shaped bodies (M) are characterized by good printability and good adhesion to coatings compared to conventional fiber-reinforced materials.

In a preferred aspect of the invention, the shaped body (M) is a shaped body (M) having the appearance of carbon fibers and no post-treatment is required. This is due to the high quality of the obtained surface, which makes no post-treatment, such as polishing and/or varnishing, necessary.

In a preferred embodiment of the invention, the thermoforming of the shaped body (M) is carried out directly after the process for preparing the fiber-reinforced composite (K), in particular before the fiber-reinforced composite (K) reaches a temperature below or equal to the glass transition temperature (Tg) of the matrix polymer composition (B). This allows the shaped body (M) to be shaped without an additional step of heating the fiber-reinforced composite material (K).

The invention also relates to a shaped body (M) obtained by the thermoforming method according to the invention.

In one aspect of the invention, the shaped body (M) is characterized in that its surface preferably has a waviness characterized by Δ w, defined as the mean height difference between the valleys and the peaks, of less than 10 μ M, preferably less than 8 μ M. This effect can be attributed in particular to the high melt volume flow rate (MVR (220/10)) of the substantially amorphous matrix polymer composition (B) compared to known matrix materials, which allows for a fast and complete impregnation of the at least one continuous fiber reinforcement material (a) with the substantially amorphous matrix polymer composition (B) even at lower temperatures. As a result, the temperature difference between the temperature required for consolidating the shaped body (M) and room temperature is small compared to known matrix materials. Furthermore, due to the amorphous character of the matrix polymer composition (B), substantially no crystallization occurs within the matrix polymer composition (B) during or after thermoforming or during application of the shaped body (M). Without being bound by theory, it is believed that this results in lower shrinkage of the matrix material after consolidation and reduced waviness observed on the surface of the shaped body (M).

The shaped bodies (M) are preferably used as elements for structural and/or aesthetic applications.

It is to be understood that the fiber-reinforced composite (K) described herein comprises one or more further features. Definitions and preferred embodiments are set forth below.

Component A

The fiber-reinforced composite (K) comprises at least one continuous fiber reinforcement (A). The at least one continuous fiber reinforcement (a) may comprise glass fibers and/or carbon fibers. In a preferred embodiment, the at least one continuous fiber reinforcement (a) consists essentially of glass fibers and/or carbon fibers. By essentially consisting of glass fibers and/or carbon fibers is meant that glass fibers and/or carbon fibers constitute at least 90 wt. -%, preferably at least 95 wt. -%, in particular at least 98 wt. -% of the at least one continuous fiber reinforcement (a), based on the total fiber material comprised in the at least one continuous fiber reinforcement (a). In another preferred embodiment, the at least one continuous fiber reinforcement (a) comprises glass fibers or carbon fibers. However, it will be appreciated that the fibre-reinforced composite material (K) may comprise a plurality of continuous fibre-reinforced materials (a), for example two or more, each of which may comprise glass fibres and/or carbon fibres, preferably glass fibres or carbon fibres.

In one embodiment of the present invention, the at least one continuous fiber reinforcement (a) comprises a plurality of at least one chemical functional group on at least a portion of at least one surface of the at least one continuous fiber reinforcement (a). Suitable functional groups include, but are not limited to, hydroxyl, ester, and/or amino groups. In a preferred embodiment, said chemical functional groups are suitable for interacting with functional groups present in at least one copolymer (B2). As will be discussed in further detail, the functional groups present in the at least one copolymer (B2) are derived from maleic anhydride and/or maleic acid moieties (i.e., repeat units derived from the (co) polymerization of maleic anhydride monomers and/or maleic acid monomers) and optionally monomers comprising additional chemical functional groups.

Preferably, the functional groups present in at least a portion of at least one surface of the at least one continuous fiber reinforcement (a) are hydroxyl groups. In another preferred embodiment, the functional groups contained in copolymer (B2) interact with the surface of the continuous fiber reinforcement (a) without affecting the degree of polymerization of copolymer (B1). This allows the interaction between the at least one continuous fiber reinforcement (a) and the matrix polymer composition (B) without reducing the overall melt volume flow rate, and the processability of the fiber-reinforced composite (K).

In one embodiment of the present invention, the continuous fiber reinforcement (a) of the present invention may optionally comprise a sizing agent applied to at least a portion of the surface of the continuous fiber reinforcement (a).

The fibres used for the fibrous reinforcement are generally treated with a sizing agent, in particular in order to protect the fibres. Preventing mutual damage due to abrasion. When mutual mechanical action occurs, cross-fragmentation (breakage) of the fibers should not occur. Furthermore, the fibers may be facilitated by sizing of the cutting process to obtain mainly the same stack length. In addition, agglomeration of the fibers can be avoided by sizing. The dispersibility of the short fibers in water can be improved. Therefore, it is possible to obtain a uniform sheet after wet-laid film formation (wet-laying process). Sizing can help to improve the adhesion between the glass fibers and the polymer matrix in which the fibers are used as reinforcing fibers. This principle is particularly applicable to Glass Fiber Reinforced Plastic (GFRP) applications. In general, sizing agents generally contain a large number of ingredients, such as film formers, lubricants, wetting agents, and binders.

The film former protects the fibers from rubbing against each other and may also enhance the affinity for the synthetic resin, thereby improving the strength and adhesion of the composite. Mention will be made of starch derivatives, polymers and copolymers of vinyl acetate and acrylic esters, epoxy resin emulsions, polyurethane resins and polyamides in proportions of from 0.5 to 12% by weight, based on the total amount of sizing.

The lubricant can soften the fiber and its product and reduce the mutual friction of the glass fibers. However, the adhesion between the glass fiber and the synthetic resin is often impaired by the use of a lubricant. Fats, oils and polyalkyleneamines are mentioned in an amount of 0.01 to 1 wt.%, based on the total amount of sizing.

Wetting agents cause a reduction in surface tension and an improvement in the wettability of the filaments with the sizing. For aqueous finishes (aqueous finishing), mention will be made, for example, of fatty acid amides present in an amount of from 0.1 to 1 to 5% by weight, based on the total amount of sizing.

There is generally no suitable affinity between the polymer matrix and the fibers. This can be overcome by a binder which increases the adhesion of the polymer on the surface of the fiber. Organofunctional silanes such as aminopropyltriethoxysilane, methacryloxypropyltrimethoxysilane, glycidyloxypropyltrimethoxysilane, and the like are typically used.

In an alternative, preferred embodiment of the invention, the continuous-fiber reinforcement (a) according to the invention is (substantially) free of sizing agent, i.e. it comprises less than 3% by weight, preferably less than 1% by weight, in particular less than 0.1% by weight, of sizing agent, based on the total weight of the continuous-fiber reinforcement (a). If the continuous-fiber reinforcement (a) according to the invention comprises a sizing agent applied to at least a part of the surface of the continuous-fiber reinforcement (a), the sizing agent is removed from the surface before application according to the invention. This can be achieved, for example, by a thermal desizing process (e.g., incineration).

In a preferred embodiment, the continuous fibrous reinforcement (a) comprises fibres having a fibre diameter substantially in the range of 5 to 20 μm, preferably 8 to 16 μm. Preferably, at least 80 wt.%, more preferably at least 90 wt.%, especially at least 95 wt.% of the fibers embedded in the continuous fiber reinforcement (a) are fibers having a fiber diameter within the specified range.

In a preferred embodiment, the fibrous continuous reinforcement (a) consists essentially of fibers having a fiber diameter in the range of 5 to 20 μm, preferably 8 to 16 μm.

The at least one continuous fiber reinforcement (a) preferably comprises fibers in the form of yarns having a linear mass density of from 100 to 5000tex, wherein the linear mass density is determined according to ISO 1144 or DIN 60905 and 1tex equals 1g/1000m fibers.

In one embodiment, the at least one continuous fiber reinforcement (a) preferably comprises fibers in the form of yarns having a linear mass density of 1000 to 5000, preferably 1000 to 4000tex, more preferably 2000 to 4000, and especially 2500 to 3500 tex. Preferably, in this embodiment, the yarns are made (substantially) of carbon fibers.

In an alternative embodiment, the at least one continuous fiber reinforcement (a) preferably comprises fibers in the form of yarns having a linear mass density of from 100 to 2000tex, preferably from 150 to 1500tex, in particular from 190 to 1250 tex. Preferably, in this embodiment, the yarns are made of (substantially) glass fibres.

The continuous fibrous reinforcement (a) consists of fibers preferably containing no short fibers ("chopped fibers"), and the fiber-reinforced composite (K) is not a short fiber reinforcement. At least 50 wt.%, preferably at least 75 wt.%, in particular at least 85 wt.% of the fibers of the continuous-fiber reinforcement (a) preferably have a length of at least 5mm, more preferably at least 10mm or more than 100 mm.

The continuous-fiber reinforcement (a) is preferably present in a layered structure (S). The skilled person knows that the layered structure (S) of the fibrous material differs from the staple fibres at least in that a continuous larger structure is formed, which structure is typically longer than 5 mm. In this case, the layered structure (S) is preferably present substantially throughout the fiber-reinforced composite material (K). This means that the layered structure (S) spreads over more than 50%, preferably at least 70%, in particular at least 90% of the length of the fiber-reinforced composite (K). The length here is the maximum extension in one of the three spatial directions. More preferably, the layered structure (S) is spread over more than 50%, preferably at least 70%, in particular at least 90% of the area of the fiber-reinforced composite (K). The area here is the area of maximum expansion in two of the three spatial directions. The continuous fiber-reinforced composite material (K) is preferably a (substantially) flat continuous fiber-reinforced composite material (K).

The at least one continuous-fiber reinforcement (a) is preferably present in the form of a layered structure, in particular in the form of an unbuckled fabric, a woven fabric, a mat, a nonwoven fabric or a knitted fabric.

In non-crimp fabrics, the fibers are ideally parallel to the front and stretched. Most use continuous fibers. The braid is formed by interweaving endless fibers (e.g., rovings). The weaving of the fibers is accompanied by the undulation of the fibers. The undulations result in particular in a reduction in the compressive strength (compressive strength) parallel to the fibers. Mats are usually composed of short and long fibers, which are loosely connected to each other by means of a binder. Nonwoven materials are structures of finite length fibers, continuous fibers (filaments), or staple yarns of any kind and of any origin that have been bonded together in some way to form a web and bonded together in some way. Knitwear (knitted fabrics) are systems of intermeshed threads.

In one embodiment, the at least one layered structure (S) of the at least one continuous fibrous reinforcement (a) is present as a woven fabric. In a preferred embodiment, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (a) is chosen from twill, satin or plain weave, and in particular twill weave.

In plain weave fabrics, the warp and weft yarns are aligned so that they form a simple criss-cross pattern. Each weft yarn intersects one warp yarn by passing over it, then passes under the next, and so on. The next weft yarn passes under the warp yarn over which its adjacent yarn passes and vice versa.

A satin weave is characterized by four or more fill yarns or weft yarns floating on one warp yarn and vice versa, four warp yarns floating on one weft yarn.

In twill weaves, each weft or fill yarn floats across the warp yarns in a staggered progression to the right or left to form a clear diagonal pattern. Such diagonal line patterns are also called wales (wales). Floats (floats) are portions of yarn that intersect two or more perpendicular yarns.

Twill weaves require three or more strands (harnesses) depending on their complexity. Twill weaves are generally designated as a fraction, such as 2/1, where the numerator represents the number of strands that are raised (hence crossed threads: two in this example) and the denominator represents the number of strands that are lowered (one in this example) when a fill yarn is inserted.

In a particularly preferred aspect of the invention, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (a) is 2/2 twill weave.

In an alternative embodiment, the at least one layered structure (S) of the at least one continuous fiber reinforcement (a) is present as a buckling-free fabric, in particular a multiaxial buckling-free fabric.

Non-crimp fabrics are typically composed of two or more plies (plies) or layers (layers) of unidirectional fibers. Each individual layer may be oriented along a different axis, and for this reason, the construction or assembly of the fabric is referred to as multiaxial. Depending on the number of layers and varying directions and axes, unidirectional, biaxial, triaxial, and quadaxial structures can be assembled into a non-crimp fabric system.

In a preferred embodiment of the invention, the at least one layered structure (S) of the at least one continuous fiber reinforcement (a) is present in the form of a biaxial non-crimp fabric, in particular a biaxial non-crimp fabric having an orientation of 0 °/90 ° or +45 °/-45 °. In the 0 °/90 ° orientation, layers with 0 ° and 90 ° orientation with respect to the longitudinal extension of the buckled fabric alternate with each other. While in the + 45/45 orientation, the alternating layers have either a +45 or-45 orientation with respect to the longitudinal extension of the buckled fabric.

The weight ratio within the woven or non-crimp fabric may be balanced or unbalanced. This means that the amount of fibers (in weight percent of the total of the at least one continuous fiber reinforcement (a)) in one direction (e.g., warp or weft in the weave and each biaxial layer in the unbuckled fabric) may occupy the total area weight at different rates. This can be achieved, for example, by using yarns having different linear mass densities in each direction (e.g., warp and weft yarns, or yarns for each oriented layer of the non-crimp fabric).

In a preferred embodiment, the at least one continuous fiber reinforcement (a) has a balanced weight ratio, i.e. a weight ratio of 50% to 50% by weight. In particular, a balanced weight ratio is preferred in woven fabrics (such as twill) as well as non-crimp fabrics.

In an alternative embodiment, the at least one continuous fiber reinforcement (a) has an unbalanced weight ratio, preferably a weight ratio of 60 to 40 to 90 to 10 wt. -%, for example a weight ratio of 80 to 20 wt. -%. In particular, unbalanced weight ratios are preferred in biaxial non-crimp fabrics. In a preferred embodiment, a biaxial non-crimp fabric having 0 °/90 ° has a balance (balance) of 60 to 90 wt% (e.g., 80 wt%) of a 0 ° oriented layer and a weight ratio of 10 to 40 wt% (e.g., 20 wt%) of a 90 ° oriented layer.

In one embodiment, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (a) is present as a nonwoven fabric, in particular having from 10 to 200g/m²Preferably 20 to 100g/m²In particular from 30 to 80g/m²Area weight of nonwoven fabric.

In a preferred embodiment, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (A) has a thickness of from 10 to 1000g/m²Area weight of (c).

In one embodiment of the present invention, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (A) preferably has a thickness of from 50 to 1000g/m²Preferably 100 to 500g/m²In particular from 150 to 300g/m²Area weight of (c). Most preferably, the layered structure (S) has 150 to 250g/m²Area weight of (c). In a preferred embodiment, at least one layered structure (S) of said at least one continuous-fiber reinforcement (a) having an areal weight in this range is (substantially) made of carbon fibers. Preferably, the at least one layered structure (S) of the at least one continuous fiber reinforcement (a) having an areal weight in this range is prepared as a twill weave, in particular an 2/2 twill weave.

In an alternative embodiment of the invention, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (A) preferably has a thickness of from 50 to 1000g/m²Preferably 200 to 750g/m²In particular 250 to 650g/m²Area weight of (c). In a preferred embodiment, at least one layered structure (S) of said at least one continuous-fiber reinforcement (a) having an areal weight in this range is made (substantially) of glass fibers. Preferably, the at least one layered structure (S) of the at least one continuous fiber reinforcement (a) having an areal weight in this range is prepared as a twill weave, in particular an 2/2 twill weave, or as a non-crimp weave, in particular having a biaxial orientation.

In another alternative embodiment of the invention, the at least one layered structure (S) of the at least one continuous-fiber reinforcement (A) preferably has a thickness of from 10 to 200g/m²Preferably 20 to 100g/m²In particular from 30 to 80g/m²Area weight of (c). In a preferred embodiment, at least one layered structure (S) of said at least one continuous-fiber reinforcement (a) having an areal weight in this range is made (substantially) of glass fibers. PreferablyAt least one layered structure (S) of said at least one continuous fiber reinforcement (a) having an areal weight in this range is prepared as a mat.

As previously mentioned, the fibre-reinforced composite material (K) comprises at least one continuous fibre-reinforcement (a), but may comprise a plurality of layered structures (S) of at least one continuous fibre-reinforcement (a). It is to be understood that each of these layered structures (S) of the at least one continuous fiber reinforcement (a) may be identical or different in terms of the fibers (e.g. material, thickness, pretreatment) comprised or the composition (e.g. with respect to form (unbuckled fabric, woven fabric, mat, non-woven fabric or knitted fabric) and/or areal weight) of the layered structure (S).

In one embodiment of the invention, each layered structure (S) of the at least one continuous fibrous reinforcement (a) has a thickness of 0.1 to 0.5mm, preferably 0.1 to 0.2mm, and the fiber-reinforced composite (K) comprises at least one layered structure (S) of the at least one continuous fibrous reinforcement (a).

As previously mentioned, the fiber-reinforced composite (K) comprises at least one continuous fiber reinforcement (a), in particular at least one layered structure (S) of the at least one continuous fiber reinforcement (a). It should be understood that the present invention is not limited to this structure. Thus, in a preferred embodiment, the fiber-reinforced composite (K) comprises a plurality of the at least one continuous fiber reinforcement (a), in particular a plurality of layered structures (S) of the at least one continuous fiber reinforcement (a), wherein each continuous fiber reinforcement (a) and/or layered structure (S) may be identical or different. This will be explained in more detail below.

Component (B)

The fiber-reinforced composite (K) comprises at least one substantially amorphous matrix polymer composition (B) comprising:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, more preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol.

The at least one substantially amorphous matrix polymer composition (B) has a glass transition temperature (Tg) of at least 100 ℃. In a preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) has a glass transition temperature (Tg) of 150 ℃ or less.

The at least one substantially amorphous matrix polymer composition (B) has a melt volume flow rate (MVR (220/10) according to ISO 1133) of 10 to 90m L/10min, preferably 30 to 80m L/10min, more preferably 40 to 70m L/10min, more preferably the melt volume flow rate (MVR (220/10) according to ISO 1133) is in the range of 45 to 60m L/10 min.

The matrix polymer composition (B) is substantially amorphous, wherein amorphous means that the macromolecules are arranged completely randomly without regular arrangement and orientation, i.e. without constant distances. Preferably, the matrix polymer composition (B) is amorphous, exhibits thermoplastic properties, and is therefore meltable and (substantially) amorphous.

Thus, the shrinkage of the matrix polymer composition (B) and thus of the entire fiber-reinforced composite (K) is relatively low. It has been found that due to the combination of these features, in particular the low molecular weight, high melt volume flow rate (MVR) and amorphous character of the matrix polymer composition (B), fiber-reinforced composites (K) can be obtained which show excellent properties with respect to producibility, processability and product properties, in particular toughness, stiffness and surface quality.

The at least one substantially amorphous matrix polymer composition (B) preferably has a molding shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range of 0.1 to 0.9%, in particular in the range of 0.2 to 0.8%.

The at least one substantially amorphous matrix polymer composition (B) preferably comprises >0 and ≦ 3 wt.%, preferably ≦ 0.1 and ≦ 2 wt.%, particularly ≦ 0.2 and ≦ 2 wt.% of repeating units derived from maleic anhydride or maleic acid. In addition, other repeating units derived from monomeric moieties may be included, which are suitable for interacting with the surface of the continuous fiber reinforcement (a). In a particularly preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) comprises ≥ 0.2 and ≤ 0.9% by weight, preferably ≥ 0.25 and ≤ 0.40% by weight, in particular ≥ 0.30 and ≤ 0.35% by weight of recurring units derived from maleic anhydride or maleic acid. In another preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) comprises no further repeating units derived from monomeric moieties suitable for interacting with the surface of the continuous fiber reinforcement (a) in addition to repeating units derived from maleic anhydride or maleic acid.

The inventors have surprisingly found that amorphous matrix polymer compositions (B) comprising a blend of the above defined copolymer (B1) and copolymer (B2) exhibit a unique and advantageous combination of properties, in particular in terms of melt volume flow rate (MVR), which gives good interpenetration of the continuous fiber reinforcement (A), and in terms of the interaction between the amorphous matrix polymer composition (B) and the continuous fiber reinforcement (A) (fiber-matrix bonding), which leads to excellent mechanical properties, wherein the amorphous matrix polymer composition (B) comprises a relatively low amount of repeating units derived from monomeric moieties suitable for interacting with the surface of the continuous fiber reinforcement (a), in particular repeating units derived from maleic anhydride or maleic acid.

Furthermore, an advantage of reducing the repeat units derived from maleic anhydride or maleic acid in the matrix polymer composition (B) is that less functional groups are present in the fiber-reinforced composite (K) which are prone to undesired side reactions, in particular decomposition reactions. It has been observed that under certain conditions, in particular at temperatures above 200 ℃, the recurring units derived from maleic anhydride or maleic acid may form gaseous products (possibly CO)₂) Is decomposed in the case of (1). Such gas formation may lead to gas encapsulation in the fiber-reinforced composite material (K) or the molded body (M), which may deteriorate the mechanical properties of the fiber-reinforced composite material (K) or the molded body (M). By reducing the amount of repeat units derived from maleic anhydride or maleic acid in the matrix polymer composition (B), it is possible to provide a fiber-reinforced composite (K) which is substantially free of gaseous inclusions and voids. The mechanical properties of the fiber-reinforced composite material (K) and of the shaped bodies (M) produced therefrom can thus be improved. Furthermore, reducing the amount of repeating units derived from maleic anhydride or maleic acid also has economic advantages, since maleic anhydride or maleic acid is more expensive and more complex to produce than styrene and acrylonitrile.

The at least one substantially amorphous copolymer (B) preferably has a molecular weight of from 1 to 1.2g/cm³In the range of 1.05 to 1.10g/cm, preferably³(iii) a density in the range of (according to ISO 1183).

The at least one substantially amorphous matrix polymer composition (B) preferably has a Vicat softening (Vicat softening) temperature (VST/B/50 according to ISO 306) of 90 to 130 ℃, in particular 95 to 120 ℃.

Preferably, the at least one substantially amorphous matrix polymer composition (B) has a viscosity number VN (determined in Dimethylformamide (DMF) according to DIN 53726) of from 45 to 75ml/g, preferably from 55 to 70ml/g, in particular from 60 to 70 ml/g.

In one embodiment of the present invention, the at least one substantially amorphous matrix polymer composition (B) preferably comprises at least one copolymer (B1) and at least one copolymer (B2), wherein the copolymer (B1) has a number average molecular weight and/or a weight average molecular weight distribution different from the number average molecular weight and/or the weight average molecular weight distribution, respectively, of the copolymer (B2). According to this aspect of the invention, the at least one substantially amorphous matrix polymer composition (B) exhibits a bimodal molecular weight distribution.

The at least one substantially amorphous matrix polymer composition (B) may preferably be obtained by blending at least one copolymer (B1), at least one copolymer (B2) and optionally at least one additive (C) in the amounts specified herein. It is to be understood that a plurality of different copolymers (B1), different copolymers (B2) and/or optionally different additives (C) may be combined to obtain the at least one substantially amorphous matrix polymer composition (B) as long as the sum of each of these compounds does not exceed a predetermined amount of the compounds defined herein.

In a preferred embodiment of the present invention, the matrix polymer composition (B) is prepared after preparation according to methods known to the person skilled in the art and is preferably processed into granules. Thereafter, the preparation of the fiber-reinforced composite (K) can be carried out.

Copolymer (B1)

The substantially amorphous matrix polymer composition (B) comprises 60 to 80 wt. -%, preferably 65 to 75 wt. -%, in particular 65 to 70 wt. -% of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile, especially at least one styrene-acrylonitrile copolymer and/or at least one α -methylstyrene-acrylonitrile copolymer, based on the total weight of the matrix polymer composition (B) preferably the at least one copolymer (B1) is a substantially amorphous copolymer of styrene or α -methylstyrene and acrylonitrile.

The copolymer (B1) is preferably selected from the group consisting of styrene-acrylonitrile copolymer (SAN), α -methylstyrene-acrylonitrile copolymer (AMSAN), impact-modified acrylonitrile-styrene copolymer, in particular acrylonitrile-butadiene-styrene copolymer (ABS), and acrylonitrile-styrene-acrylate copolymer (ASA). however, in a preferred embodiment, the copolymer (B1) is not an impact-modified copolymer.

Preferably, the at least one copolymer (B1) is chosen from at least one substantially amorphous styrene-acrylonitrile copolymer (SAN) and/or at least one amorphous α -methylstyrene-acrylonitrile copolymer (AMSAN), in particular at least one amorphous styrene-acrylonitrile copolymer (SAN).

Generally, any SAN and/or AMSAN copolymer known in the art may be used within the subject matter of the present invention. In a preferred embodiment, the SAN and AMSAN copolymers of the present invention comprise:

-50 to 99 wt% of at least one selected from styrene and α -methylstyrene, based on the total weight of the SAN and/or AMSAN copolymer, and

-from 1 to 50% by weight of acrylonitrile, based on the total weight of SAN and/or AMSAN copolymer.

Particularly preferred weight ratios of the components making up the SAN or AMSAN copolymer are 60 to 95 wt% (based on the total weight of the SAN and/or AMSAN copolymer) of styrene and/or α -methylstyrene and 40 to 5 wt% (based on the total weight of the SAN and/or AMSAN copolymer) of acrylonitrile.

Particularly preferred are SAN or AMSAN copolymers containing acrylonitrile monomer units in an incorporation ratio of < 36% by weight, based on the total weight of the SAN and/or AMSAN copolymer.

More preferred are copolymers of styrene and acrylonitrile of the SAN or AMSAN type incorporating relatively little acrylonitrile (not more than 35% by weight, based on the total weight of the SAN and/or AMSAN copolymer).

Most preferred are copolymers based on:

-from 65 to 81% by weight, preferably from 70 to 80% by weight, based on the total weight of the SAN and/or AMSAN copolymer, of at least one selected from styrene and α -methylstyrene, and

19 to 35% by weight, preferably 20 to 30% by weight, of acrylonitrile, based on the total weight of SAN and/or AMSAN copolymer.

In one embodiment, the at least one copolymer (B1) is an AMSAN copolymer.

In an alternative, particularly preferred embodiment, the at least one copolymer (B1) is a SAN copolymer.

In a preferred embodiment of the present invention, the copolymer (B1) is a copolymer obtained by copolymerizing a monomer mixture comprising:

from ≥ 74 to ≤ 78% by weight, preferably from ≥ 75 to ≤ 77% by weight, based on the total weight of the SAN copolymer, of styrene, and

-from ≥ 22 to ≤ 26% by weight, preferably from ≥ 23 to ≤ 25% by weight, based on the total weight of the SAN copolymer, of acrylonitrile.

The at least one copolymer (B1) preferably has a number average molecular weight Mn of from 30,000 to 100,000g/mol, preferably from 40,000 to 90,000g/mol, and in particular from 50,000 to 80,000 g/mol. The weight-average molecular weight Mw is generally in the range from 55,000 to 250,000g/mol, preferably from 80,000 to 225,000g/mol, and in particular from 90,000 to 200,000 g/mol. In a particularly preferred embodiment, the at least one copolymer (B1) preferably has a number average molecular weight Mn of from 55,000 to 75,000g/mol and a weight average molecular weight Mw in the range from 125,000 to 185,000 g/mol. Typically, molecular weight is determined by Gel Permeation Chromatography (GPC) using Tetrahydrofuran (THF) as the solvent in combination with an RI/UV detector. Calibration was performed using anionic polymerized monodisperse polystyrene calibration standards.

The polydispersity index (PDI) of the copolymer (B1) is generally in the range from 1.5 to 3, preferably from 1.7 to 2.7, in particular from 1.9 to 2.6. PDI is calculated as PDI — Mw/Mn.

The at least one copolymer (B1) preferably has a viscosity number VN (determined in DMF according to DIN 53726) of from 45 to 75ml/g, preferably from 55 to 70ml/g, in particular from 60 to 70ml/g, which is particularly preferred.

The at least one copolymer (B1) preferably has a density of less than 1.2g/cm³Preferably between 1 and 1.19g/cm³Density within the range (determined according to ISO 1183).

The at least one copolymer (B1) preferably has a melt volume flow rate (MVR (220/10)) of from 10 to 90m L/10min, preferably from 30 to 80m L/10min, more preferably from 50 to 80m L/10min, and in particular from 56 to 80m L/10min in one embodiment the (MVR (220/10)) of the at least one copolymer (B1) is in the range of from 60 to 80ml/10min, preferably from 60 to 70ml/10min, typically from 63 to 66ml/10min (determined according to ISO 1133).

The at least one copolymer (B1) preferably has a molding shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range of 0.1 to 0.9%, in particular in the range of 0.2 to 0.8%.

Preferably, the at least one copolymer (B1) is a (substantially) amorphous, (substantially) amorphous thermoplastic polymer.

The at least one copolymer (B1) preferably has a vicat softening temperature (VST/B/50 according to ISO 306) of from 90 to 130 ℃, in particular from 95 to 120 ℃.

SAN and AMSAN copolymers are known and their preparation (e.g., by free radical polymerization, more particularly by emulsion, suspension, solution and bulk polymerization) is well documented in the literature. Preferably, a solution polymerization process is employed (for example, as described in patent application GB 1472195A).

Component (B2)

The at least one substantially amorphous matrix polymer composition (B) further comprises from 20 to 40 wt. -%, preferably from 25 to 35 wt. -%, in particular from 30 to 35 wt. -%, of at least one copolymer (B2) of styrene, acrylonitrile, maleic anhydride and/or maleic acid with optional monomers comprising additional chemical functional groups suitable for interacting with the surface of the continuous fiber reinforcement (a), based on the total weight of the matrix polymer composition (B). In particular, the chemically reactive functional groups contained in maleic anhydride, maleic acid or optionally monomers comprising further chemical functional groups are capable of reacting with chemical groups located on at least a part of the surface of the fibrous reinforcement (a) during the manufacturing of the continuous fiber-reinforced composite (K).

Thus, copolymer (B2) imparts a functional group to matrix polymer composition (B) that causes copolymer (B2) to act as a compatibilizer between copolymer (B1) and continuous fiber reinforcement (a). This is achieved by the interaction between the functional groups of the copolymer (B2) and the functional groups present on at least a part of the surface of the at least one continuous fiber reinforcement (a). Due to their similar chemical properties, the copolymers (B1) and (B2) are highly compatible and compatibility between the copolymer (B1) and the at least one continuous fiber reinforcement (a) is achieved.

It is to be understood that the polar functional groups contained in copolymer (B2) preferably interact with the surface of the continuous fiber reinforcement (a) without affecting the degree of polymerization of copolymer (B1), thus leaving the total melt volume flow rate of copolymer (B1) unchanged.

Suitable monomers carrying functional groups include, in addition to maleic anhydride and/or maleic acid, monomers which are capable of forming bonds, in particular covalent bonds, with functional groups of the fibre material (a), such as hydroxyl groups, ester groups and/or amino groups. Preferred monomers are those capable of reacting with hydroxyl or amino groups and forming covalent bonds.

According to one embodiment, the monomer is selected from the group consisting of N-Phenylmaleimide (PM), t-butyl (meth) acrylate and glycidyl (meth) acrylate. According to a preferred embodiment, the monomer is selected from the group consisting of N-Phenylmaleimide (PM) and glycidyl (meth) acrylate (GM).

However, according to a particularly preferred embodiment, the copolymer (B2) comprises only functional groups suitable for interacting with the surface of the continuous-fiber reinforcement (a) and derived from maleic anhydride and/or maleic acid.

Thus, in another preferred embodiment, the at least one copolymer (B2) is obtained by copolymerization of styrene, acrylonitrile, maleic anhydride and/or maleic acid, in particular by copolymerization of styrene, acrylonitrile and maleic anhydride.

Preferred copolymers (B2) are prepared by copolymerizing a monomer composition having the following composition:

(b2-i)60 to 90 wt% styrene;

(b2-ii)9.9 to 39.9 weight percent acrylonitrile; and

(b2-iii)0.1 to 10 weight percent maleic anhydride;

wherein (b2-i), (b2-ii), and (b2-iii) total 100 wt%.

In another preferred embodiment, the at least one copolymer (B2) is obtained by copolymerizing a monomer mixture having the following composition:

(b2-i)70 to 80 wt% styrene;

(b2-ii)19.9 to 29.9 weight percent acrylonitrile; and

(b2-iii)0.1 to 5 weight percent maleic anhydride;

wherein (b2-i), (b2-ii), and (b2-iii) total 100 wt%.

In another preferred embodiment, the at least one copolymer (B2) is obtained by copolymerizing a monomer mixture having the following composition:

(b2-i)74 to 76 wt% styrene;

(b2-ii)21 to 25.5 weight percent acrylonitrile; and

(b2-iii)0.5 to 3 weight percent maleic anhydride;

wherein (b2-i), (b2-ii), and (b2-iii) total 100 wt%.

In a preferred embodiment of the present invention, the at least one copolymer (B2) is obtained by copolymerizing a monomer mixture comprising from 0.75 to 2.5% by weight of maleic anhydride, based on the total weight of the copolymer of styrene, acrylonitrile and maleic anhydride.

In a preferred embodiment of the present invention, the at least one copolymer (B2) is obtained by copolymerizing a monomer mixture comprising from 0.75 to 1.25% by weight of maleic anhydride, based on the total weight of the styrene, acrylonitrile and maleic anhydride copolymers.

In an alternative preferred embodiment of the invention, the at least one copolymer (B2) is obtained by copolymerizing a monomer mixture comprising from 2.0 to 2.2% by weight of maleic anhydride, based on the total weight of the styrene, acrylonitrile and maleic anhydride copolymers.

The at least one copolymer (B2) preferably has a number average molecular weight Mn of from 30,000 to 100,000g/mol, preferably from 40,000 to 90,000g/mol, in particular from 45,000 to 75,000 g/mol. The weight-average molecular weight Mw is generally in the range from 55,000 to 250,000g/mol, preferably from 80,000 to 225,000g/mol, in particular from 90,000 to 200,000 g/mol. In a particularly preferred embodiment, the at least one copolymer (B2) preferably has a number-average molecular weight Mn of from 45,000 to 65,000g/mol and a weight-average molecular weight Mw in the range from 105,000 to 165,000 g/mol. Typically, molecular weight is determined by Gel Permeation Chromatography (GPC) using Tetrahydrofuran (THF) as the solvent in combination with an RI/UV detector. Calibration was performed using anionic polymerized monodisperse polystyrene calibration standards.

The polydispersity index (PDI) of the copolymer (B2) is generally in the range from 1.5 to 3, preferably from 1.7 to 2.7, in particular from 1.9 to 2.6. PDI is calculated as PDI — Mw/Mn.

The at least one copolymer (B2) preferably has a molding shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range from 0.1 to 0.9%, in particular in the range from 0.2 to 0.8%.

Preferably, the at least one copolymer (B2) is a (substantially) amorphous, (substantially) amorphous thermoplastic polymer.

The copolymer (B2) preferably has a Vicat softening temperature (VST/B/50 according to ISO 306) of from 95 to 120 ℃, in particular from 100 to 110 ℃.

The at least one substantially amorphous copolymer (B2) preferably has a molecular weight in the range of from 1 to 1.2g/cm³In the range of 1.05 to 1.10g/cm, preferably³(iii) a density within the range of (determined according to ISO 1183).

The at least one copolymer (B2) preferably has a melt volume flow rate (MVR (220/10)) of from 10 to 60m L/10min, preferably from 15 to 40m L/10min, in particular from 20 to 30m L/10min (determined according to ISO 1133).

Preferably, the at least one copolymer (B2) has a Viscosity Number (VN) of from 75 to 90ml/g, in particular from 77 to 85 ml/g.

Copolymers (B2) are generally known in the art, and their preparation methods (e.g., by free radical polymerization, more particularly by emulsion, suspension, dissolution and bulk polymerization) are well documented in the literature. Preferably, a solution polymerization process is employed (for example, as described in patent application GB 1472195A).

Component C

The fiber-reinforced composite (K) may optionally contain, as further component (C), from 0 to 40% by weight, preferably from 0 to 30% by weight, particularly preferably from 0 to 10% by weight, based on the total weight of components (a) to (C), of one or more additives (auxiliaries and additives) which are different from components (a) and (B). In a preferred embodiment, the fiber-reinforced composite (K) does not comprise an additive (C) which is gaseous at a temperature below 350 ℃, in particular below 300 ℃. This reduces the release and loss of these additives during the production of the fiber-reinforced composite material (K) and/or the shaped body (M).

In one embodiment of the present invention, the fiber-reinforced composite (K) comprises substantially no additives (C), i.e. not more than 1% by weight, preferably not more than 0.5% by weight, based on the total weight of components (a) to (C). However, if additives (C) are present, it is preferred to mix the optional additives (C) with the matrix polymer composition (B) before preparing the fiber-reinforced composite (K).

As optional additives (C) there will be mentioned particulate mineral fillers, processing aids, stabilizers, antioxidants, agents against thermal and uv decomposition, lubricating and mold release agents, flame retardants, dyes and pigments, and plasticizers. In addition, esters as low molecular weight compounds may be mentioned. According to the present invention, two or more of these compounds may be used. Generally, the compounds have a molecular weight of less than 3000g/mol, preferably less than 150 g/mol.

For example, the particulate mineral filler may be obtained, for example, in the form of: amorphous silica, carbonates (e.g. magnesium carbonate, calcium carbonate (chalk)), powdered quartz, mica, various silicates (e.g. clay, muscovite, biotite, phlogopite (suzorite), tin maleate, talc, chlorite, phlogopite, feldspar), calcium silicates (e.g. wollastonite or kaolin, especially calcined kaolin).

Uv stabilizers include, for example, various substituted resorcinols, salicylates, benzotriazoles and benzophenones, which are generally used in amounts of up to 2% by weight, based on the total matrix polymer composition (B).

According to the present invention, the thermoplastic molding composition of the matrix polymer composition (B) may comprise an antioxidant and a heat stabilizer. Sterically hindered phenols, hydroquinones, substituted representatives of this group, secondary aromatic amines, optionally in combination with phosphorus-containing acids or salts thereof, and mixtures of these compounds may be used in amounts of preferably up to 1% by weight, based on the total weight of the matrix polymer composition (B).

Other additives according to the present invention include lubricants and release agents, which are typically added in amounts of up to 1% by weight of the matrix polymer composition (B). Mention will be made here of stearyl alcohol, alkyl stearates and amides, preferablyAnd esters of pentaerythritol with long chain fatty acids. Calcium, zinc or aluminium salts of stearic acid and dialkyl ketones, for example distearyl ketone, may also be used. In addition, ethylene oxide-propylene oxide copolymers may be used as lubricants and release agents. In addition, natural and synthetic waxes may be used. These include PP wax, PE wax, PA wax, PO graft wax, HDPE wax, PTFE wax, EBS wax, candelilla wax, carnauba wax, and beeswax.

The flame retardant may be a halogen-containing or halogen-free compound. Suitable halogen-containing compounds remain stable during the manufacture and processing of the fiber-reinforced composite (K) and/or the matrix polymer composition (B) according to the invention, so that corrosive gases are not released and the effect is not impaired. Brominated compounds are preferred over the corresponding chlorinated compounds. Preference is given to using halogen-free compounds, such as phosphorus compounds, in particular phosphine oxides and derivatives of the acids of phosphorus as well as salts of the acids and acid derivatives of phosphorus. Particularly preferred phosphorus compounds comprise esters, alkyl groups, cycloalkyl groups and/or aryl groups.

Further suitable additives are oligomeric phosphorus compounds having a molecular weight of less than 2000g/mol, as described, for example, in EP-A0363608.

Pigments and dyes may also be included. They are generally present in an amount of from 0 to 15% by weight, preferably from 0.1 to 10% by weight, in particular from 0.5 to 8% by weight, based on the total weight of the components (B) to (C) included. Pigments for coloring thermoplastics are well known, see for exampleMuller, Taschenbuch derkunststoffadd, Carl Hanser Verlag, 1983, pages 494 to 510.

A first group of preferred pigments to be mentioned are white pigments, such as zinc oxide, zinc sulfide, white lead (PbCO)₃)₂·Pb(OH)₂Lithopone (lithopone), antimony trioxide and titanium dioxide. Of the two most common crystalline polymorphs (rutile and anatase) of titanium dioxide, the rutile form is preferred for white coloration of the moulding compositions according to the invention.

Black pigments which can be used according to the invention are black iron oxide (Fe)₃O₄) Spinel black (Cu (Cr, Fe)₂O₄) Manganese black (a mixture of manganese dioxide, silicon oxide and iron oxide), cobalt black and antimony black, carbon black, usually in the form of furnace black, is particularly preferably used (see g. benzing, pigment f ü r austichmittel, Expert-Verlag (1988), pp 78 ff).

Of course, inorganic color pigments (such as chromium oxide green) or organic color pigments (such as azo pigments and phthalocyanines) can be used to adjust certain hues. Such pigments are generally commercially available.

Furthermore, it may be advantageous to use the abovementioned pigments or dyes in the form of mixtures (for example mixtures of carbon black with copper phthalocyanines) because of the ease of colouring in the polymer.

Fiber reinforced composite material (K)

The fiber-reinforced composite (K) according to the invention comprises at least one continuous fiber reinforcement (a) and at least one substantially amorphous matrix polymer composition (B), wherein the at least one continuous fiber reinforcement (a) and the at least one substantially amorphous matrix polymer composition (B) are as defined above. In particular, the fiber-reinforced composite (K) according to the invention comprises ≥ 50% by weight, based on the total weight of the fiber-reinforced composite (K), of at least one continuous fiber reinforcement and ≥ 50% by weight, based on the total weight of the fiber-reinforced composite (K), of at least one substantially amorphous matrix polymer composition (B).

The inventors have surprisingly found that the specific composition of the substantially amorphous matrix polymer composition (B) allows the preparation of a fiber-reinforced composite (K) having a high amount of at least one continuous fiber reinforcement (A) of more than or equal to 50 wt.% (based on the total weight of the fiber-reinforced composite (K)), while improving the processability of the fiber-reinforced composite (K), in particular in connection with the thermoforming process, to obtain the shaped body (M). At the same time, the surface properties of the fiber-reinforced composite (K) and of the shaped body (M) are improved in comparison with known composites, while the good mechanical properties are not substantially affected.

In one embodiment of the present invention, the fiber-reinforced composite (K) may advantageously comprise ≥ 50% by weight and ≤ 80% by weight, based on the total weight of the fiber-reinforced composite (K), of at least one continuous fiber-reinforcement (A). In another embodiment, the fiber-reinforced composite (K) comprises ≥ 50% by weight to ≤ 60% by weight (e.g. 51% by weight to 59% by weight) of the at least one continuous fiber reinforcement (A), based on the total weight of the fiber-reinforced composite (K). In an alternative embodiment, the fiber-reinforced composite (K) comprises ≥ 60% by weight and ≤ 70% by weight (e.g. 61% by weight and 69% by weight) of the at least one continuous fiber reinforcement (A), based on the total weight of the fiber-reinforced composite (K).

Thus, in one embodiment of the present invention, the fiber-reinforced composite (K) may advantageously comprise from >20 to <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of the at least one substantially amorphous matrix polymer composition (B). In another embodiment, the fiber reinforced composite (K) may comprise >40 to <50 wt. -% of the at least one substantially amorphous matrix polymer composition (B), based on the total weight of the fiber reinforced composite (K). In an alternative embodiment, the fiber-reinforced composite (K) may comprise >30 to <40 wt. -%, based on the total weight of the fiber-reinforced composite (K), of the at least one substantially amorphous matrix polymer composition (B).

In another embodiment of the invention, the at least one continuous fiber reinforcement (a) preferably constitutes 35 to 55 volume-%, preferably 40 to 50 volume-%, in particular 45 to 47 volume-%, of the entire fiber-reinforced composite (K), based on the volume of the fiber-reinforced composite (K).

The at least one continuous fiber reinforcement (a) may be embedded in the fiber-reinforced composite (K) in any orientation and position and is preferably completely encapsulated by the at least one substantially amorphous matrix polymer composition (B). This means that the outer surface of the entire fiber-reinforced composite (K) is preferably formed by the at least one substantially amorphous matrix polymer composition (B).

The continuous fiber reinforcement (a) is preferably not distributed statistically uniformly in the fiber-reinforced composite (K), but in the layered structure (S) with a higher or lower fiber percentage (thus as more or less separate layers). Thus, the fiber-reinforced composite (K) contains a layered structure (S) of substantially flat layers of the at least one continuous fiber reinforcement (a) and a layer of a substantially amorphous matrix polymer composition (B) comprising the at least one copolymer (B1) and the at least one copolymer (B2) and optionally additives (C). However, it is to be understood that the substantially amorphous matrix polymer composition (B) also extends throughout the substantially flat layer of the at least one continuous fiber reinforcement (a).

As previously mentioned, in one embodiment of the invention, the fiber-reinforced composite (K) comprises at least one layered structure (S) of continuous fiber reinforcement (a). In another preferred embodiment, the fiber-reinforced composite (K) may preferably comprise a plurality of continuous fiber reinforcements (a), in particular a plurality of layered structures (S) (i.e. a plurality of layers) of the at least one continuous fiber reinforcement (a). Each layered structure (S) (or layer) may be the same or different. It should be understood that the different layers may vary in particular in the following respects: yarn (especially for fiber diameter and/or linear mass density), form of the continuous fiber reinforcement (a) (e.g. unbuckled, woven, mat, non-woven, etc.) and specific areal weight. The layered structure (S) is stacked within the fiber-reinforced composite material (K). In a preferred embodiment, each layered structure (S) is embedded in the fiber-reinforced composite material (K) in the same orientation and position. In an alternative preferred embodiment, each layered structure (S) is embedded in the fiber-reinforced composite material (K) in the same position, but in an orientation rotated by 90 ° compared to the adjacent layered structure (S). By each of these stacking sequences, a preferred laminate is formed.

In another preferred embodiment, the fiber-reinforced composite (K) comprises from 1 to 12, preferably from 2 to 6 layered structures (S) (or layers) of continuous fiber reinforcement (a). Each layered structure (S) (or layer) of the continuous fiber reinforcement (a) may be the same or different. It is to be understood that the layered structure (S) (or layer) may vary in particular in terms of yarn (in particular for fiber diameter and/or linear mass density), form of the continuous fiber reinforcement (a) (e.g. unbuckled or woven, mat, non-woven, etc.) and specific areal weight.

In one aspect of the invention, the fiber-reinforced composite (K) comprises 1 to 10, preferably 2 to 6, in particular 4, layered structures (S) (or layers) of woven or non-crimp fabrics as continuous fiber reinforcement (a). In this aspect of the invention, each layer of continuous fibrous reinforcement (a) may be the same or different, and is preferably the same.

In another embodiment of this aspect of the invention, said laminate comprising 1 to 10, preferably 2 to 6, in particular 4, layered structures (S) (or layers) of woven or non-crimp fabric as continuous fiber reinforcement (a) further comprises at least one layered structure (S) of nonwoven fabric on the upper and lower side of the laminate. This means that the first and last layered structure (S) in each stacking or stacking sequence of the fibre-reinforced composite material (K) is a non-woven fabric. The inventors have found that the nonwoven fabric as the last layered structure (S) on each side of the laminate further improves the surface properties of the fibre-reinforced composite (K) in terms of optical appearance and smoothness.

In a preferred embodiment, at least 50%, preferably at least 65%, in particular at least 80% of the number of layered structures (S) in the fiber-reinforced composite (K) is woven or non-crimp fabric, and at most 50%, preferably at most 35%, in particular at most 20% of the number of layered structures (S) may be non-woven fabric.

The fiber-reinforced composite material (K) can be shaped into a shaped body (M) in a thermoforming process. As will be discussed in detail, the fibre-reinforced composite material (K) has a relatively wide temperature range in which the shaped body (M) can be formed in a thermoforming process. In particular, the thermoforming process may be carried out at a temperature in the range of 150 ℃ below the temperature required for softening the fibre-reinforced composite material (K). According to a further aspect of the invention, the fiber-reinforced composite (K) can be molded in a thermoforming process carried out at a temperature of at least 160 ℃, preferably 150 ℃, in particular 140 ℃.

Method for producing fiber-reinforced composite material (K)

The fibre-reinforced composite (K) can be prepared by any method known in the art which is suitable for preparing fibre-reinforced composites. However, in a preferred embodiment, the fiber-reinforced composite (K) is obtained by a process comprising at least one step, wherein the continuous fiber reinforcement (a) is impregnated with a substantially liquid melt of a substantially amorphous matrix polymer composition (B), in particular at a temperature in the range of 230 to 330 ℃, preferably 250 to 300 ℃, in particular 270 to 290 ℃.

This temperature range has been found to be particularly suitable for achieving a complete impregnation of the at least one continuous fiber reinforcement (a) with the substantially amorphous matrix polymer composition (B). Also under these conditions, the preferably complete interaction between the at least one continuous-fiber reinforcement (a) and the copolymer (B2) occurs rapidly, resulting in improved fiber-matrix adhesion.

More particularly, the fiber-reinforced composite (K) is preferably prepared by a process comprising at least the following steps:

(a) providing at least one continuous fibrous reinforcement (a), preferably at least one layered structure (S) of said at least one continuous fibrous reinforcement (a);

(b) providing at least one substantially amorphous matrix polymer composition (B);

(c) applying said at least one substantially amorphous matrix polymer composition (B) onto at least one surface of said at least one continuous fiber reinforcement (a) to obtain a layered arrangement;

(d) heating the layered arrangement obtained in step (c) to a first temperature (T1) to obtain a substantially liquid matrix polymer composition (B), the first temperature (T1) being sufficiently above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B);

(e) impregnating the at least one continuous fibrous reinforcement material (a) with a substantially liquid matrix polymer composition (B);

(f) cooling the thus obtained polymer impregnated continuous fiber reinforcement (a) to a second temperature (T2) to obtain a fiber reinforced composite (K), said second temperature (T2) being below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B);

in the process, in particular the process steps (d) and/or (e) are carried out at a temperature in the range from 230 to 330 ℃, preferably from 250 to 300 ℃, in particular from 270 to 290 ℃. It has been found that said temperature range is particularly suitable for achieving a complete impregnation of said at least one continuous fibrous reinforcement material (a) with said substantially amorphous matrix polymer composition (B). Also under these conditions, the preferably complete interaction between the at least one continuous-fiber reinforcement (a) and the copolymer (B2) occurs rapidly, resulting in improved fiber-matrix adhesion.

With respect to the at least one continuous fibrous reinforcement (a) and the at least one substantially amorphous matrix polymer composition (B), the above definitions and preferred embodiments apply. In particular, the at least one substantially amorphous matrix polymer composition (B) comprises at least one copolymer (B1) and at least one copolymer (B2).

More particularly, the fiber-reinforced composite (K) is preferably prepared by a process comprising at least the following steps:

(a) providing ≥ 50 wt.% of at least one continuous-fiber reinforcement (A), preferably at least one layered structure (S) of said at least one continuous-fiber reinforcement (A), based on the total weight of the fiber-reinforced composite (K);

(b) providing <50 wt. -%, based on the total weight of the fiber-reinforced composite (K), of at least one matrix polymer composition (B) comprising:

(B1) 60 to 80 wt.%, preferably 65 to 75 wt.%, in particular 65 to 70 wt.%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α -methylstyrene and acrylonitrile having a number-average molecular weight Mn of 30,000 to 100,000g/mol, preferably 40,000 to 90,000g/mol, and

(B2) 20 to 40 wt. -%, preferably 25 to 35 wt. -%, in particular 30 to 35 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 suitable for interacting with the surface of the at least one continuous fiber reinforcement (a), said copolymer having a number average molecular weight Mn of 30,000 to 100,000g/mol, preferably 45,000 to 75,000 g/mol;

(c) applying said at least one matrix polymer composition (B) onto at least one surface of said at least one continuous fiber reinforcement (a) to obtain a layered arrangement;

(d) heating the layered arrangement obtained in step (c) to a first temperature (T1) to obtain a substantially liquid matrix polymer composition (B), the first temperature (T1) being sufficiently higher than the glass transition temperature (Tg) of the at least one matrix polymer composition (B);

(e) impregnating the at least one continuous fibrous reinforcement material (a) with the substantially liquid matrix polymer composition (B);

(f) cooling the thus obtained polymer-impregnated continuous fiber reinforcement (a) to a second temperature (T2) to obtain a fiber-reinforced composite (K), the second temperature (T2) being lower than the glass transition temperature (Tg) of the at least one matrix polymer composition (B);

wherein the at least one matrix polymer composition (B) has a glass transition temperature (Tg) in the range of from 100 ℃ to 150 ℃ and a melt volume flow rate (MVR (220/10) according to ISO 1133) of from 10 to 90m L/10min, preferably from 30 to 80m L/10min, more preferably from 40 to 70m L/10min, in particular from 45 to 60m L/10 min.

In one embodiment of the present invention, the fiber-reinforced composite (K) may further comprise at least one additive (C). Although it may generally be added in any process step, it is preferred to mix the at least one additive (C), if present, with the at least one substantially amorphous matrix polymer composition (B) before providing the at least one substantially amorphous matrix polymer composition (B) in process step (B). The preparation of blends of thermoplastic polymers and additives is known in the art. Any known method may be used. For example, the optional additive (C) may be added during or after the polymerization of any of the copolymers (B1) and/or (B2). Alternatively, the optional additive (C) may be added during blending of the copolymer (B1) and/or (B2) to obtain the at least one substantially amorphous matrix polymer composition (B). Alternatively, the optional additive (C) may be mixed with the at least one substantially amorphous matrix polymer composition (B) in a separate process step.

The at least one substantially amorphous matrix polymer composition (B) may be provided in any known form (e.g. in the form of granules, powder, foil, melt). In a preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) is provided to the process in the form of a substantially liquid melt. The substantially liquid melt can be prepared, for example, in optionally heatable mixing devices, for example discontinuously operating heated internal kneading devices with or without RAM, continuously operating kneaders (for example continuous internal kneaders, screw kneaders with axially oscillating screws, Banbury kneaders, also extruders, and roll mills, mixing roll mills with heated rolls and calenders). In a preferred embodiment, these mixing devices may also be used for the blending of components (B1), (B2) and optionally (C) to obtain the at least one substantially amorphous matrix polymer composition (B).

By "substantially liquid" or "substantially liquid melt" is meant that the at least one substantially amorphous matrix polymer composition (B) and the major liquid melt (softened) portion may further comprise a proportion of solid components, e.g., which are unmelted fillers and reinforcing materials (e.g., glass fibers, metal flakes), or unmelted pigments, colorants, and the like. By "liquid melt" is meant a polymer mixture that has at least low flow properties and therefore softens to at least some degree to impart plasticity.

Applying said at least one substantially amorphous matrix polymer composition (B) onto at least one surface of said at least one continuous fiber reinforcement (a) to obtain a layered arrangement. In one embodiment, the at least one substantially amorphous matrix polymer composition (B) may be applied to more than one surface of the at least one continuous fiber reinforcement (a) to obtain a layered arrangement, in particular at least two surfaces, preferably two opposing surfaces.

In a preferred embodiment, the first temperature (T1) is in the range of 1 to 200 ℃, preferably 10 to 190 ℃ above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) and the second temperature (T2) is in the range of 1 to 50 ℃ below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B). Preferably, the first temperature (T1) is in the range of 180 ℃ to 300 ℃, preferably 200 ℃ to 260 ℃. In another preferred embodiment, the second temperature (T2) is in the range of 70 ℃ to 100 ℃, preferably 75 ℃ to 90 ℃.

It has been found that said temperature range of said first temperature (T1) is particularly suitable for achieving a complete impregnation of said at least one continuous fibrous reinforcement material (a) with said substantially amorphous matrix polymer composition (B). Moreover, under these conditions, the preferably complete interaction between the at least one continuous-fiber reinforcement (a) and the copolymer (B2) occurs rapidly. Furthermore, curing below said second temperature (T2) allows good control of the shape and surface properties of the fibre-reinforced composite material (K).

In one embodiment of the process for preparing the fiber-reinforced composite (K), at least one of the process steps (d) to (f) is carried out under elevated pressure, preferably in the range from 1.5 to 3MPa, in particular in the range from 1.8 and 2.3 MPa. Preferably, at least the process step (f) is carried out at elevated pressure, preferably in the range from 1.5 to 3MPa, in particular in the range from 1.8 to 2.3MPa, and the elevated pressure is applied in step (f) until the second temperature (T2) is reached.

In one embodiment of the invention, the fiber-reinforced composite (K) is made of a plurality of continuous fiber reinforcements (a), in particular of a plurality of layered structures (S) of the at least one continuous fiber reinforcement (a), preferably 1 to 12, in particular 2 to 6, for example 3, 4 or 5. In this embodiment, the at least one substantially amorphous matrix polymer composition (B) may be provided separately to each layered structure (S) of the at least one continuous fiber reinforcement material (a). However, in a preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) is provided in the form of a substantially liquid melt in the central laminar position of the stack or stacking sequence of the layered structure (S). It has been found that due to the relatively high melt volume flow rate of the matrix polymer composition (B), the substantially liquid melt of the at least one substantially amorphous matrix polymer composition (B) is suitable for impregnating the entire layered structure (S) under the conditions of the manufacturing process.

However, in order to further improve the surface smoothness of the fiber-reinforced composite (K), a further amount of the amorphous matrix polymer composition (B) may be applied onto the outer surface of the upper and lower (first and last) layered structure (S) of the at least one continuous fiber reinforcement (a) in each stack or stacking sequence. In a particularly preferred embodiment, these upper and lower (first and last) layer structures (S) in each stacking or stacking sequence are non-woven fabrics, in particular glass fiber non-woven fabrics. Preferably, the nonwoven fabric is provided with an additional amount of amorphous matrix polymer composition (B) in powder form or in particulate form, which is at least substantially homogeneously distributed on the outermost surface of the nonwoven fabric. In one embodiment of this aspect of the invention, 70 to 90 wt% of the total amorphous matrix polymer composition (B) is provided, preferably in the form of a substantially liquid melt, to the center of the stack/laminate of layered structures (S) of the at least one continuous fiber reinforcement (a), and 5 to 30 wt% of the total amorphous matrix polymer composition (B) is provided, preferably in the form of a powder or granules, onto the upper and lower (first and last) layered structures (S) of the at least one continuous fiber reinforcement (a) in each stacking or stacking sequence.

In one aspect of this embodiment, said laminate comprising 1 to 10, preferably 2 to 6, especially 4, layered structures (S) (or layers) of woven or non-crimp fabric as continuous fiber reinforcement (a) further comprises at least one layered structure (S) of nonwoven fabric on the upper and lower side of the laminate. This means that the first and last layered structure (S) in each stacking or stacking sequence of the fibre-reinforced composite material (K) is a non-woven fabric. The inventors have found that the nonwoven fabric as the last layered structure (S) on each side of the laminate further improves the surface properties of the fibre-reinforced composite (K) in terms of optical appearance and smoothness.

The method may preferably further comprise a consolidation step, wherein gas encapsulation in the fiber-reinforced composite (K) is reduced and a good bond is formed between the at least one continuous reinforcement (a) and the at least one amorphous matrix polymer composition (B). Preferably, a (substantially) pore-free fiber-reinforced composite (K) is obtained after impregnation and consolidation.

In an alternative embodiment, the described method steps may be performed in a separate order. For example, first a layered structure (S) of the at least one continuous reinforcement (a) may be prepared, whereby the reinforcement (a) is impregnated with the at least one matrix polymer composition (B). Subsequently, a predetermined number of impregnated layered structures (S) of the at least one continuous reinforcement material (a) may be combined in a stacked/laminated form and may then be consolidated in a further method step to form the fiber-reinforced composite (K).

Before impregnating the reinforcement (a) with the matrix polymer composition (B), at least a portion of the reinforcement (a) may be pretreated to affect, preferably improve, the fiber-matrix bonding after. The pre-treatment may for example comprise a coating step, an etching step, a heat treatment step or a mechanical surface treatment step. In particular, the adhesion promoter and/or sizing agent that has been applied can be at least partially removed, for example, by heating a portion of the reinforcing material (a).

The fiber-reinforced composite (K) according to the invention can be obtained by the method. However, in an alternative embodiment, the fiber-reinforced composite material (K) can be further processed, in particular in a thermoforming process, to produce the shaped body (M).

Production of the shaped bodies (M)

The fiber-reinforced composite material (K) described herein is used as a starting material for the shaping of shaped bodies (M) in a thermoforming process. In particular, the three-dimensional shaped body (M) is preferably produced from the fiber-reinforced composite material (K) by the method described below. However, the shaping of the shaped body (M) may also comprise the shaping of a substantially two-dimensional body, wherein further materials are applied to at least one surface of the fiber-reinforced composite material (K). Alternatively, a thermoforming process may also be applied to further improve the surface properties of the fiber-reinforced composite (K).

The method for thermoforming a fiber-reinforced composite material (K) into a shaped body (M) comprises at least the following steps:

(i) providing a fiber-reinforced composite (K) as described herein;

(ii) heating the fiber-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 fiber-reinforced composition (K) in a mold at a mold surface temperature (T4) to obtain a shaped body (M);

(iv) demoulding the moulded body (M) from a mould;

wherein the mold surface temperature (T4) is equal to or greater than 50 ℃.

The fibre-reinforced composite (K) in step (i) is preferably provided by a method according to the above-described method.

In method step (ii), the fiber-reinforced composite material (K) is then heated to a temperature (T3). This step may be accomplished by any heating means known in the art suitable for heating the fibrous reinforcement. Suitable heating means employ, for example, infrared radiation, hot air or a hot surface of the forming device, wherein the surface is preferably heated by a heat transfer medium such as oil within the forming device or by an induction heating device. In a preferred embodiment, infrared radiation is used as the heating means. In an alternative embodiment, a hot surface of the forming device is used. The surface may be heated, in particular by an induction heating device.

The temperature (T3) is the temperature at which the at least one substantially amorphous matrix polymer composition (B) is substantially softened and in particular liquid. The fiber-reinforced composite material (K) can thus be formed into the desired shape of the molded body (M). Preferably, the temperature (T3) is below the decomposition temperature of the at least one substantially amorphous matrix polymer composition (B), preferably below 300 ℃. This reduces the decomposition of the matrix polymer composition (B) and the release of decomposition products. In a particularly preferred embodiment, the temperature (T3) in process step (ii) is in the range from ≥ 200 ℃ and ≤ 280 ℃, in particular in the range from ≥ 220 ℃ and ≤ 250 ℃. This ensures that the temperature of the fiber-reinforced composite material (K) is sufficiently high for the thermoforming process step (iii) even if the heated fiber-reinforced composite material (K) has to be transferred from the heating device used in process step (ii) to the forming apparatus used in process step (iii).

The thermoforming step (iii) of the process for the preparation of the shaped bodies (M) can be carried out in any apparatus known in the art, provided that the above defined temperature ranges are observed. Preferably, the thermoforming step (iii) is carried out under elevated pressure to obtain a precisely shaped body (M). In particular, the pressure applied is ≥ 0.1MPa, more preferably ≥ 0.3 MPa. In one embodiment, the pressure applied is 10MPa or less, in particular 5MPa or less. In a particularly preferred embodiment of the invention, the pressure applied is in the range ≥ 0.5MPa and ≤ 2.0 MPa. It is particularly preferred that the fibre-reinforced composite (K) heated in step (ii) has a temperature of at least 170 ℃ to 180 ℃ before entering step (iii).

The mold surface temperature (T4) represents the temperature of the mold surface that comes into contact with the surface of the fiber-reinforced composite material (K) when the fiber-reinforced composite material (K) is molded into the shape of the molded body (M). The surface temperature (T4) of the mould is more than or equal to 50 ℃ so as to form the fiber reinforced composite material (K).

In one embodiment of the present invention, the mold surface temperature (T4) is in the range of 50 ℃ or higher and 90 ℃ or lower, preferably 60 ℃ or higher and 80 ℃ or lower. This results in the formation of a shaped body (M) which can be released from the mold without further cooling. In this case, the shaped body (M) is sufficiently cured immediately after the thermoforming process, since the mold surface temperature (T4) is below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B). Method step (iv) is then correspondingly carried out by opening the mold or the molding device.

However, in a preferred embodiment of the present invention, the mold surface temperature (T4) is higher than the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably 10 to 50 ℃, in particular 20 to 40 ℃ higher than the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B). In a preferred embodiment, the mold surface temperature (T4) is in the range of 130 ℃ or more and 210 ℃ or less, preferably 140 ℃ or more and 200 ℃ or less. In another preferred embodiment, the mold surface temperature (T4) is in the range of 140 ℃ to 170 ℃, preferably in the range of 140 to 160 ℃. The inventors of the present application found that a mold surface temperature in this range allows thermoforming the fiber-reinforced composite material (K) into a molded body (M) having an abnormally smooth surface.

If the mold surface temperature (T4) is higher than the glass transition temperature (Tg), at least the surface of the molded body (M) must be cooled and sufficiently solidified before releasing the molded body (M) from the mold. In particular, the surface of the shaped body (M) has to be cooled to a temperature below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B), preferably at least 5 ℃, in particular at least 15 ℃ below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B). In a preferred embodiment, this is achieved by a process (hereinafter also referred to as variable mold temperature process) comprising the following process steps:

(i) providing a fiber-reinforced composite (K) as described herein;

(ii) heating the fiber-reinforced composite (K) to a temperature (T3) at which the at least one substantially amorphous matrix polymer composition (B) is substantially softened;

(iii) (a) thermoforming the fiber-reinforced composition (K) in a mold at a first mold surface temperature (T4) to obtain a shaped body (M);

(b) reducing the temperature of the mold surface to a second mold surface temperature (T5) to cure at least the surface of the shaped body (M), the second mold surface temperature (T5) being below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B);

(iv) demolding the molded body (M) from the mold;

wherein the first mold surface temperature (T4) is at least 10 ℃ to 50 ℃, particularly at least 20 ℃ to 40 ℃, higher than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B) and the second mold surface temperature (T5) is at least 5 ℃, particularly at least 15 ℃, lower than the glass transition temperature (Tg) of the at least one substantially amorphous polymer composition (B).

This method is called a variable mold temperature method. The variable mold temperature method is characterized in that the temperature of the hot forming method can be controlled at each point in the method. This is achieved by using a device, in particular a molding device, which allows to control and regulate the surface temperature of the device (or mold) by actively heating and/or cooling the mold surface. This can be achieved by a heat transfer medium (e.g. water or oil) which circulates within the device, i.e. in direct contact with the device surface, in particular with the mould surface.

In a preferred embodiment, the thermoforming process is carried out in a forming apparatus that allows for variable mold temperature processing using an induction heating apparatus. Since the heating phase of the induction heating device is short, the required cycle time can be significantly reduced. By using the variable mold temperature method, further improvement of the surface of the molded body (M) can be achieved. By rapidly cooling the mold after completion of thermoforming, at least the surface of the molded body (M) can be cooled to a temperature lower than the glass transition temperature (Tg) of the matrix polymer composition (B) within the mold. Since the matrix polymer composition (B) has a relatively low glass transition temperature (Tg) and substantially no crystallization occurs in the substantially amorphous matrix polymer composition (B), only a small shrinkage of the shaped body (M) occurs after demolding from the processing apparatus. This further improves the smoothness of the surface of the molded body (M).

By applying a processing device using induction heating, the heating and cooling rates can be further accelerated, thereby increasing the described effects and advantages. The cooling is preferably achieved by an internal cooling circuit comprising water, glycol and/or oil.

It has been found that if a thermoplastic styrene-based polymer having a melt volume flow rate (MVR according to ISO1133 (220/10)) of 10 to 90m L/10min is selected as the matrix polymer composition (B), the variable mould temperature process can achieve fast processing cycles and produce a high quality surface of the fibre-reinforced composite.

In one embodiment of the invention, at least one of the process steps (i), (ii) and/or (iii) is carried out in an apparatus allowing variable mold temperature processing, in particular variable mold temperature processing using induction heating. This allows rapid temperature changes of the fiber-reinforced composite material (K) and/or of the shaped body (M), which are accompanied by short cycle times and a high surface quality of the shaped body (M), i.e. a low waviness of the shaped body (M).

Further, as is apparent from the above, the temperature range in which the thermoforming process can be carried out is in the range of (T3) <300 ℃ and (T4) ≥ 50 ℃, particularly in the range of ≤ 280 ℃ to ≥ 130 ℃. The temperature range in which the fiber-reinforced composite (K) has sufficient moldability is therefore in excess of 150 ℃ and preferably in excess of 250 ℃. Such a wide processing temperature range is not known for conventional fiber reinforced materials and provides greater flexibility in the forming process.

Furthermore, the reinforced composite (K) exhibits unique processability due to the unique combination of the plurality of continuous fiber reinforcement (a), the high specific melt volume flow rate (MVR) and molecular weight of the substantially amorphous matrix polymer composition (B), and the high fiber-matrix adhesion resulting from the bonds formed between the continuous fiber reinforcement (a) and the copolymer (B2): in the inventive process for the preparation of shaped bodies (M) as described herein, the substantially amorphous matrix polymer composition (M) is substantially free from decomposition, degassing and/or dripping.

In a preferred embodiment, the at least one substantially amorphous matrix polymer composition (B) has a molding shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range of 0.1 to 0.9%, in particular in the range of 0.2 to 0.8%. This further results in shaped bodies (M) having a high surface quality, in particular having a low degree of surface waviness. In a particularly preferred embodiment of this aspect of the invention, shaped bodies (M) are obtained wherein the surface of the shaped bodies (M) has a waviness characterized by Δ w, defined as the mean height difference between the troughs and the peaks, of less than 10 μ M, preferably less than 8 μ M.

In a further aspect of the invention, the method for thermoforming a fiber-reinforced composite material (K) into a shaped body (M) may comprise further method steps, in particular method steps suitable for applying a coating and/or printing onto at least one surface of the shaped body (M).

In one embodiment of this aspect of the invention, the process further comprises a treatment step, wherein a film (F), in particular a decorative film, is applied to at least one surface of the fiber-reinforced composite (K) before the thermoforming step (iii). The film (F) is preferably a polymer film comprising at least one styrene-containing copolymer, in particular at least one acrylonitrile-butadiene-styrene copolymer (ABS copolymer).

The film (F) preferably has a decoration which is suitable for providing the shaped body (M) with a desired surface appearance or design.

In an alternative embodiment, it is also possible to apply the film (F) to the surface of the shaped body (M) after carrying out process step (iii). However, in this aspect of the invention, an additional processing step is required in which the film (F) is applied to at least one surface of the shaped body (M). The laminate thus obtained is heated to a temperature which allows the formation of a bond between the film (F) and the shaped body (M), preferably to a temperature between the above-mentioned temperatures (T3) and (T4). Optionally, in a preferred embodiment, pressure is applied to at least a portion of the surface of the laminate so obtained. In particular, the applied pressure is at least 0.1MPa or more, more preferably 0.3MPa or more. In one embodiment, the applied pressure is ≦ 10MPa, specifically ≦ 5 MPa. In a particularly preferred embodiment, the applied pressure is in the range ≥ 0.5MPa and ≤ 2.0 MPa. This method step is particularly recommended if the film (F) is sensitive (e.g. very thin), or if the shape of the shaped body (M) is very complex, and if the film (F) may be damaged during shaping of the shaped body (M) if applied before the thermoforming step (iii).

In a further aspect of the invention, the method may further comprise a method step, wherein the shaped body (M) is further processed by applying a coating and/or printing on at least one surface of the shaped body (M). The fiber-reinforced composite material (K) as well as the molded body (M) comprise surfaces which have a relatively high polarity compared to conventional thermoplastic fiber-reinforced materials and are therefore suitable for coating with coatings or printing materials, such as paints or inks. The coating or print exhibits excellent adhesion to the surface of the fiber-reinforced composite material (K) or the molded body (M).

In a further aspect of the invention, a process for producing a shaped body (M) from a fiber-reinforced composite material (K) is used for producing a shaped body (M) having the appearance of carbon fibers, i.e. having an optical appearance, wherein the fiber material embedded in the shaped body (M) is visible on at least a part of the surface of the shaped body (M). The previous definitions and preferred embodiments generally apply with regard to the design of components (a), (B1), (B2) and (C), if present, and also the fiber-reinforced composite (K) and the process for its preparation.

The molded body (M) having the appearance of carbon fibers is produced from a fiber-reinforced composite material (K) which comprises glass fibers and/or carbon fibers as at least one continuous reinforcing material (a), preferably at least one continuous reinforcing material (a) consisting essentially of carbon fibers. In particular, the at least outermost continuous reinforcement (a), i.e. the continuous reinforcement (a) intended to be visible in the shaped body (M) having the appearance of carbon fibers, consists essentially of carbon fibers. Preferably, the continuous reinforcement (a) is at least one selected from non-crimp fabric or woven fabric. The non-crimp fabric or woven fabric may be selected based on the desired optical appearance. In one embodiment of the invention, the continuous reinforcement (a) is a woven fabric, in particular selected from twill weaves. The at least one continuous-fiber reinforcement (a) constitutes 35 to 55 vol.%, preferably 40 to 50 vol.%, in particular 45 to 47 vol.%, of the entire shaped body (M) having the appearance of carbon fibers.

In a preferred aspect of this embodiment, the at least one substantially amorphous matrix polymer composition (B) has a melt volume flow rate (MVR (220/10) according to ISO 1133) of 40 to 70m L/10min, more preferably 45 to 60m L/10min, and a molding shrinkage according to ISO294-4 of less than 1.5%, preferably less than 1%, more preferably in the range of 0.1 to 0.9%, in particular in the range of 0.2 to 0.8%.

The combination of these specific components (a) and (B) allows the processing of the fiber-reinforced composite material (K) into shaped bodies (M) having the appearance of carbon fibers within a significantly reduced cycle time (0.1 to 10 minutes, preferably 0.2 to 7 minutes, more preferably 0.3 to 5 minutes, in particular 0.5 to 3 minutes), wherein the cycle time defines the time required for preparing one shaped body (M) in the shaping apparatus, i.e. the time required for carrying out the process steps comprising at least process steps (iii) and (iv), preferably at least process steps (ii), (iii) and (iv).

Preferably, the molded body (M) having the appearance of carbon fibers is produced using the above-described variable mold temperature method. This may further improve the surface quality and thus the appearance of the carbon fibers. In a particularly preferred embodiment of the invention, shaped bodies (M) are obtained having the appearance of carbon fibers, wherein the surface of the shaped bodies (M) has a waviness characterized by Δ w, defined as the mean height difference between the valleys and the peaks, of less than 10 μ M, preferably less than 8 μ M. This allows the preparation of high quality surfaces without the need for further surface treatments such as polishing or applying a clear coat. Therefore, no post-processing is required.

The process for producing the shaped body (M) or the shaped body (M) having the appearance of carbon fibers from the fiber-reinforced composite material (K) can be carried out as a single process. Thus, in step (i) of the above method, a finished fiber-reinforced composite (K) is provided. However, in an alternative embodiment, the thermoforming of the shaped body (M) is carried out directly after the production process of the fiber-reinforced composite material (K). In particular, in this aspect of the invention, the thermoforming of the shaped body (M) is carried out before the fiber-reinforced composite (K) reaches a temperature of not more than the Tg of the at least one substantially amorphous matrix polymer composition (B). Preferably, the thermoforming of the shaped body (M) is carried out after step (e) of the above-described method for producing a fiber-reinforced composite material (K) and before step (f) of the method for producing a fiber-reinforced composite material (K). This results in a further reduction in cycle time and a reduction in the energy required for heating.

The molded body (M) or the molded body (M) having the appearance of carbon fibers can be further processed by injection molding or pressing of the functional element. Further cost advantages can result since further mounting steps (e.g. soldering functional elements) can be omitted.

By applying a reinforcing structure to at least a part of the shaped body (M) or the shaped body (M) having the appearance of carbon fibers, the shaped body (M) or the shaped body (M) having the appearance of carbon fibers can be further supported to improve mechanical properties, in particular stiffness. In particular, a rib structure can be applied to at least one surface of the shaped body (M) or of the shaped body (M) having the appearance of carbon fibers. Generally, the optimal rib size calculation includes production technology, aesthetics, and construction aspects. The rib structure can be formed in particular by a back-injection molding method after forming the molded body (M) or the molded body (M) having the appearance of carbon fibers. In an alternative embodiment, the mechanical properties of the shaped body (M) or of the shaped body (M) having the appearance of carbon fibers are improved by secondary shaping.

The invention also relates to a shaped body (M) or a shaped body (M) having the appearance of carbon fibres obtained by the thermoforming process described herein.

Applications of

The field of use of the fiber-reinforced composite material (K) and/or the shaped body (M) is wide. The fiber-reinforced composite material (K) and/or the shaped body (M) can be used as an element for structural and/or aesthetic applications. The fiber-reinforced composite material (K) and/or the molded body (M) can therefore be used in fields in which the following materials are required: these materials are capable of absorbing relatively high forces under load before complete failure and provide high strength and rigidity at the same low density as well as other advantageous properties such as good resistance to ageing and corrosion.

Since an exceptionally smooth surface can be obtained for the fiber-reinforced composite material (K) and/or the molded body (M), specific applications are possible in which the fiber-reinforced composite material (K) and/or the molded body (M) are visible components, such as applications in the interior and/or exterior of automobiles.

Furthermore, due to the high smoothness of the surface and the high translucency of the matrix material (B), the fiber-reinforced composite material (K) and/or the shaped body (M) are particularly suitable for applications requiring a shaped body (M) having the appearance of carbon fibers, i.e. applications in which the structure of the continuous reinforcing material (a), in particular comprising carbon fibers, is visible from the outside.

In a further aspect of the invention, the fiber-reinforced composite material (K) and/or the shaped body (M) can be further treated, preferably by applying a coating to the surface, in particular for decorative purposes.

Without being limited thereto, possible applications are for example in the automotive field (e.g. seat structures, front end modules, door carriers, firewalls, center consoles, body panels, interior trim, parts with a carbon fibre appearance), healthcare (e.g. insoles, prostheses, orthotics), sports and leisure (e.g. ski helmets, bicycle parts, two-board skis, one-board skis, drones, scale models) and electronic equipment (e.g. back covers for tablet computers, laptops, mobile phones and other mobile devices).

The invention is further illustrated by the following figures, examples and claims.

Drawings

Fig. 1a shows a photograph of a fracture surface obtained in a fatigue test carried out on a composite material comprising a polyamide matrix.

Fig. 1b shows an enlarged cross-section of the photograph of fig. 1 a.

Fig. 2a shows a photograph of a fracture surface obtained in a fatigue test performed on a composite material according to the invention.

Fig. 2b shows an enlarged cross-section of the photograph of fig. 2 a.

Fig. 3a shows a shaped body prepared according to the invention at a mold surface temperature of 160 ℃.

Fig. 3b shows a shaped body prepared according to the invention at a mold surface temperature of 190 ℃.

Fig. 4a shows a shaped body made from a composite material comprising a polyamide matrix at a mold surface temperature of 160 ℃.

Fig. 4b shows a shaped body made from a composite material comprising a polyamide matrix at a mold surface temperature of 190 ℃.

Fig. 5a shows a molded body prepared using a mold surface temperature of 80 ℃.

Fig. 5b shows a shaped body prepared according to the invention at a mold surface temperature of 160 ℃.

Fig. 5c shows a shaped body prepared according to the invention at a mold surface temperature of 190 ℃.

Examples

General procedure

The weight average molecular weight and number average molecular weight were determined by gel permeation chromatography on a standard column with monodisperse polystyrene calibration standards.

The melt volume flow rate (MVR (220/10) was determined according to ISO 1133.

The Viscosity Number (VN) is generally determined in accordance with DIN53726 at 25 ℃ using a 0.5% by weight solution of the polymer in Dimethylformamide (DMF).

The Vicat softening temperature is typically determined as VST/B/50 according to ISO 306.

Mold shrinkage is generally determined according to ISO 294-4.

The polymer density is generally determined according to ISO 1183.

Fibre reinforcementMechanical Properties of the composite Material

The following experiments were carried out on a batch hot press capable of producing fiber/film composites of polymer film, melt or powder for the quasi-continuous production of fiber-reinforced thermoplastic semi-finished products, laminates and sandwich panels.

The technical data of the intermittent hot press for the melt are：

Plate width: 660mm

Thickness of the laminate: 0.2 to 9.0mm

Laminate tolerance: corresponding to the maximum plus or minus 0.1mm of the semi-finished product

Thickness of the sandwich panel: maximum 30mm

And (3) outputting: depending on the mass and build thickness, about 0.1-60m/h,

nominal feed rate: 5m/h

Tool pressure: pressing unit 5-25bar, variable (optional) for minimum and maximum tool size

Controlling the temperature of the die: 3 heating zones and 2 cooling zones

Temperature of the cutter: a maximum temperature of 400 DEG C

Length of the cutter: 1000mm

Opening a press: 0.5 to 200mm

Preferred production direction: from right to left

Technical data of melt plasticization:

discontinuous application of a melt in an intermediate layer for producing a fiber-reinforced thermoplastic semi-finished product

Screw diameter: 35mm

Maximum displacement (max): 192cm³

Maximum screw rotation speed: 350rpm

Maximum discharge flow rate: 108cm³/s

Maximum discharge pressure: 2406bar specific

And:

melt volume: 22ccm

Isobar (isobar) pressure controlled pressing process

Isovolumetric line (isochor) volume controlled pressing process

T [ deg.C ] (temperature of temperature region)

(the press has 3 heating zones and 2 cooling zones in the production direction)

P bar ═ pressure per cycle: equal volume 20

S [ mm ] -travel limit Press thickness (travel limit Press thickness): 1.1mm

Temperature profile: (i)210 ℃ to 245 ℃ and thus about 220 DEG C

(ii)300 ℃ to 325 ℃ and thus about 300 DEG C

(iii)270 ℃ to 320 ℃ and thus about 280 ℃ to 320 DEG C

(iv)160 ℃ to 180 DEG C

(v)80℃

T [ sec ] is the pressing time per cycle: 20-30s

Construction/lamination: a 6-layer structure with a melt interlayer; a method of manufacture; direct melting

Components

Continuous fiber reinforcement (A)

A1: glass twill 2/2 having an areal weight of about 290g/m²(type: 011020800-.

A2: glass twill 2/2 having an areal weight of about 320g/m²(type: EC 14-320-350; manufacturer: PD Glasseide GmbH Oschatz).

A3: a glass fiber nonwoven fabric having a surface area weight of about 50g/m²(type: Evalith S5030, manufacturer: Johns Manville Europe).

Matrix Polymer (B)

B1 styrene/acrylonitrile (S/AN) copolymer with a composition of 76% by weight of styrene (S) and 24% by weight of Acrylonitrile (AN), AN Mw of 135,000g/mol (determined by gel permeation chromatography on a standard column with monodisperse polystyrene calibration standards), AN MVR (220/10) of 64m L/10min (determined according to ISO 1133), and a viscosity number (determined according to DIN53726 in DMF) VN of 64 g/ml.

B2 styrene/acrylonitrile/maleic anhydride (S/AN/MSA) copolymer of composition (wt%) 75/24/1, concentration of functional groups 75 wt% of S (104.2g/mol) and 1 wt% of MSA (98.1g/mol) in 25 wt% of AN (53.1g/mol), Mw of 131,000g/mol, Mn of 58,000 and 60,000g/mol (determined by gel permeation chromatography on a standard column with monodisperse polystyrene calibration standards), MVR (220/10) of 22m L/10min (determined according to ISO 1133), viscosity number (determined according to DIN53726 in DMF) VN of 80 g/ml.

B3 blend of B1 and B2 in the ratio B2: B1: 1:2, functional group concentration 0.33 wt.% MSA, MVR (220/10) 50m L/10min (determined according to ISO 1133), viscosity number (determined according to DIN53726 in DMF) VN 65 g/ml.

B4 styrene/acrylonitrile/maleic anhydride (S/AN/MSA) copolymer with a composition (% by weight) of 73.9/24/2.1, a concentration of functional groups of 73.9% by weight of S (104.2g/mol) and 24% by weight of 2.1% by weight of MSA (98.1g/mol) in AN (53.1g/mol), AN Mw of 116,000g/mol, AN Mn of 50,000 and 64,000g/mol (determined by gel permeation chromatography on a standard column with monodisperse polystyrene calibration standards), AN MVR (220/10) of 22m L/10min (determined according to ISO 1133), and a viscosity number (determined according to DIN53726 in DMF) VN of 80 g/ml.

PC (OD): flowable, amorphous polycarbonate (optical grade for optical discs).

PA 6: semi-crystalline, free-flowing polyamide durothan B30S.

In order to investigate the E-modulus and the flexural strength, the following fiber-reinforced composite materials were prepared, in which flat fiber materials were respectively introduced. The prepared fiber composites each had a thickness of about 1.1 mm. To prepare a black sample, 2 wt% carbon black was added to the polymer matrix.

Table 1. design of the fiber reinforced composite studied.

For the samples described in table 1, the following mechanical properties were determined according to DIN EN ISO 14125.

TABLE 2 mechanical Properties of the fiber-reinforced composites according to the study of TABLE 1