Abstract:
A resin composition having laser marking properties on radiation from a Nd:YAG laser wherein said composition comprises a polyester thermoplastic resin, a sufficient amount of light pigment for forming a light background coloration, and an effective amount of marking agent wherein said polyester thermoplastic resin decomposes in laser struck areas to form dark colored markings in laser struck areas on the light background coloration wherein the marking agent is selected from the group consisting of copper fumarates and copper maleates and mixtures thereof.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from Provisional Application Ser. No. 60/197,764, filed Apr. 17, 2000. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to a resin composition suitable for marking with a laser and a method for laser marking. 
     BACKGROUND OF THE INVENTION 
     The laser beam provides a means of writing, bar coding and decorative marking of plastics. This technique is advantageous over current printing technologies because of the ease at which the layout can be adjusted using graphic computer programs and also integrated into the production line. Laser marking enables a contact-free procedure even on soft, irregular surfaces that are not readily accessible. In addition it is ink-free which makes it long-lasting and solvent-free and, thus, more friendly to the environment. Speeds up to 10,000 mm/sec are possible with a CO 2  laser while Nd:YAG laser allows up to 5000 mm/sec. 
     There are several laser types available for marking plastic surfaces. The Excimer laser with the frequency in the range of 196-351 nm leads to the marking of plastic surfaces by photochemical ablation or reaction. Using Nd:YAG laser at lower power levels at 532 nm provides laser marking by leaching or selective bleaching of dyes and pigments while the Nd:YAG laser at 1064 nm leads to laser marking by carbonization, sublimation, discoloration, thermochemical reaction, foaming and engraving. The CO 2  laser at 10600 nm enables laser marking by thermochemical reaction, melting, vaporizing and engraving. 
     In many instances, it is desirable to form a dark contrast on a light background. EP 0 111 357 uses metal silicates to obtain black markings on articles having a polyolefin surface. U.S. Pat. No. 4,578,329 to Holsappel describes the use of a silicon compound, preferably a metal silicate, e.g. calcium-metasilicate or kaoline to give a black mark in the laser struck areas of a polyolefin. 
     U.S. Pat. No. 5,489,639 to Faber et al describes the use of copper phosphate, copper sulfate and copper thiocyanate with a thermoplastic resin to give dark markings. EP 400,305 describes copper hydroxy phosphate and EP 697,433 describes the use of copper sulfate. JP 04052190 to DAINIPPON INK&amp;CHEM KK describes a laser marking method giving high contrast black images by laser irradiating surface of resin composition containing bismuth, nickel and/or copper. Mentioned is the use of copper oxalate and copper citrate components that are known to cause splay and/or discoloration at the processing temperatures typically used for engineering thermoplastics like PBT, PP and PA. 
     It is desirable to make further improvements in laser marking materials of the polyester type. In particular, a desired color combination is a light background color and a dark contrast color in the laser treated areas. In particular, it is desirable to obtain a dark contrast color in the laser treated areas using a Nd:YAG laser. With increased power output/writing speed Nd:YAG lasers are nowadays more and more preferred, based on their flexibility in terms of text and images. The Nd:YAG laser enables laser marking based on several phenomena, such as melting, thermochemical reaction, vaporizing and carbonization. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to provide crystalline resin compositions containing ingredients selected to enhance the laser marking of resins with the laser so light background coloration can be achieved with distinct and secure dark colored markings in the laser treated areas. The ever increasing demand for higher laser marking speeds and productivity combined with good contrast between the laser-marked part and the background stretches today&#39;s additive technology. In fact with today&#39;s technology the new targets are hard if not impossible to reach. 
     For copper salts such as copper hydroxy phosphate (EP 400 305), copper phosphate and copper sulfate (EP 697 433), a possible mechanism is the conversion of the copper salt are converted to copper oxide, yielding a black marking. Organic copper salts, like copper carbonate, copper oxalate are even more effective, probably because the conversion to copper oxide occurs at lower temperatures. However, these materials cannot effectively be used in relatively high-melting thermoplastics like PBT, PET, PP and the like because of discoloration during compounding or molding or issues related to the formation of volatile by-products. 
     It was surprisingly found that the copper fumarates and copper maleates did not show this kind of splay or degradation and yielded very black markings. It outperforms copper pyrophosphates and copper phosphates, particularly at low loadings. Moreover, these copper fumarates and copper maleates comply with the environmental labels like Blue Angel. Processing studies in PBT show that the copper fumarates can be compounded at melttemperatures up to 300° C. without any problem with splay or degradation. 
     A resin composition having laser marking properties comprises a polycrystalline thermoplastic resin such as a polyester or polyamide, a sufficient amount of light pigment for forming a light background coloration, and an effective amount of marking to form dark colored markings in laser struck areas. The marking agent is selected from the group consisting of copper fumarates and copper maleates and mixtures thereof. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The marking agent is selected from the group consisting of copper fumarates and copper maleates and mixtures thereof. 
     The exact nature of the mechanism by which these additives work is not yet established. It is thought to be a combination of increased absorption of the laser light and an increased tendency towards the formation of an oxide of copper. 
     Additionally the resin contains a sufficient amount of light pigment for forming a light background coloration. This pigmentation can be in the form of various pigments and dyes such as set forth in the examples that are compatible with the resin. Pigments are generally present in an amount from 0.01 to 4 percent by weight. 
     Polyesters include those comprising structural units of the following formula:                           
     wherein each R 1  is independently a divalent aliphatic, alicyclic or aromatic hydrocarbon or polyoxyalkylene radical, or mixtures thereof and each A 1  is independently a divalent aliphatic, alicyclic or aromatic radical, or mixtures thereof. Examples of suitable polyesters containing the structure of the above formula are poly(alkylene dicarboxylates), liquid crystalline polyesters, and polyester copolymers. It is also possible to use a branched polyester in which a branching agent, for example, a glycol having three or more hydroxyl groups or a trifunctional or multifunctional carboxylic acid has been incorporated. Furthermore, it is sometimes desirable to have various concentrations of acid and hydroxyl end groups on the polyester, depending on the ultimate end-use of the composition. 
     The R 1  radical may be, for example, a C 2-10  alkylene radical, a C 6-12  alicyclic radical, a C 6-20  aromatic radical or a polyoxyalkylene radical in which the alkylene groups contain about 2-6 and most often 2 or 4 carbon atoms. The A 1  radical in the above formula is most often p- or m-phenylene, a cycloaliphatic or a mixture thereof. This class of polyester includes the poly(alkylene terephthalates). Such polyesters are known in the art as illustrated by the following patents, which are incorporated herein by reference. 
     
       
         
               
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 2,465,319 
                 2,720,502 
                 2,727,881 
                 2,822,348 
               
               
                   
                 3,047,539 
                 3,671,487 
                 3,953,394 
                 4,128,526 
               
               
                   
                   
               
             
          
         
       
     
     Examples of aromatic dicarboxylic acids represented by the dicarboxylated residue Al are isophthalic or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether, 4,4′ bisbenzoic acid and mixtures thereof. Acids containing fused rings can also be present, such as in 1,4- 1,5- or 2,6-naphthalenedicarboxylic acids. The preferred dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid or mixtures thereof. 
     The most preferred polyesters are poly(ethylene terephthalate) (“PET”), and poly(1,4-butylene terephthalate), (“PBT”), poly(ethylene naphthanoate) (“PEN”), poly(butylene naphthanoate), (“PBN”) and (polypropylene terephthalate) (“PPT”), and mixtures thereof. 
     Also contemplated herein are the above polyesters with minor amounts, e.g., from about 0.5 to about 5 percent by weight, of units derived from aliphatic acid and/or aliphatic polyols to form copolyesters. The aliphatic polyols include glycols, such as poly(ethylene glycol) or poly(butylene glycol). Such polyesters can be made following the teachings of, for example, U.S. Pat. Nos. 2,465,319 and 3,047,539. 
     The preferred poly(1,4-butylene terephthalate) resin used in this invention is one obtained by polymerizing a glycol component at least 70 mol %, preferably at least 80 mol %, of which consists of tetramethylene glycol and an acid or ester component at least 70 mol %, preferably at least 80 mol %, of which consists of terephthalic acid, and polyester-forming derivatives therefore. 
     The polyesters used herein have an intrinsic viscosity of from about 0.4 to about 2.0 dl/g as measured in a 60:40 phenol/tetrachloroethane mixture or similar solvent at 23°-30° C. Preferably the intrinsic viscosity is 1.1 to 1.4 dl/g. VALOX Registered TM 325 polyester is particularly suitable for this invention. 
     From the above description, it is apparent that present compositions which contain laser marking additives form distinct marks at the higher temperatures utilized with certain lasers. 
     Additionally, the preferred resin compositions of the present invention may include reinforcing glass fibers. The fibrous glass comprises from 5 to 40 weight percent, preferably from about 10 to about 30 percent by weight based on the total weight. The glass fiber or filamentous glass is desirable employed as reinforcement in the present compositions. Glass that is relatively soda free is preferred. The low soda glass known as “C” glass may be utilized. For electrical uses, fibrous glass filaments comprised of lime-aluminum borosilicate glass that is relatively soda-free which is known as “E” glass may be used. The filaments are made by standard processes, e.g., by steam or air blowing, flame blowing and mechanical pulling. The preferred filaments for plastic reinforcement are made by mechanical pulling. The filament diameters range from about 3 to 30 microns inch but this is not critical to the present invention. 
     In preparing the molding compositions it is convenient to use the filamentous glass in the form of chopped strands of from about ⅛″ to about ½″ long. In articles molded from the compositions on the other hand, even shorter lengths will be encountered because, during compounding considerable fragmentation will occur. This is desirable, however, because the best properties are exhibited by thermoplastic injection molded articles in which the filament lengths lie between about 0.000005″ and 0.125 (⅛″). 
     Additionally, flame-retardant may be added. The amount of flame-retardant additive should be present in an amount at least sufficient to reduce the flammability of the polyester resin, preferably to a UL94 V-0 rating. The amount will vary with the nature of the resin and with the efficiency of the additive. In general, however, the amount of additive will be from 2 to 20 percent by weight based on the weight of resin. A preferred range will be from about 5 to 15 percent. 
     Typically halogenated aromatic flame-retardants include tetrabromobisphenol A polycarbonate oligomer, polybromophenyl ether, brominated polystyrene, brominated BPA polyepoxide, brominated imides, brominated polycarbonate, poly (haloaryl acrylate), poly (haloaryl methacrylate), or mixtures thereof. Poly (haloaryl acrylate) is preferred with the most preferably being poly (pentabromobenzyl acrylate). PBB-PA has been known for some time, and is a valuable flame-retardant material, useful in a number of synthetic resins. PBB-PA is prepared by the polymerization of pentabromobenzyl acrylate ester (PBB-MA). The PBB-PA polymeric flame-retardant material is incorporated into the synthetic resin during processing to impart flame retardant characteristics. 
     Examples of other flame retardants are brominated polystyrenes such as polydibromostyrene and polytribromostyrene, decabromobiphenyl ethane, tetrabromobiphenyl, brominated alpha, omega-alkylene-bis-phthalimides, e.g. N,N′-ethylene-bis-tetrabromophthalimide, oligomeric brominated carbonates, especially carbonates derived from tetrabromobisphenol A, which, if desired, are end-capped with phenoxy radicals, or with brominated phenoxy radicals, or brominated epoxy resins. Other aromatic carbonate flame retardants are set forth in U.S. Pat. No. 4,636,544 to Hepp. 
     Flame retardants are typically used with a synergist, particularity inorganic antimony compounds. Such compounds are widely available or can be made in known ways. Typical, inorganic synergist compounds include Sb 2 O 5 ; SbS3; and the like. Especially preferred is antimony trioxide (Sb 2 O 3 ). Synergists such as antimony oxides, are typically used at about 0.5 to 15, and more preferably from 1 to 6 percent by weight based on the weight percent of resin in the final composition. 
     In an effort to avoid the utilization of antimony compounds, is preferable not to use the halogenated flame retardants and the antimony synergtist. Preferably non-halogenated flame retardants are utilized. Typical non-halogenated flame retardant includes phosphorus containing compositions such as phosphoric acids, pyro/polyphosphates, and organic esters of phosphinic and phosphonic acids. Phosphoric acids include phosphoric acid, pyrophosphoric acid through metaphosphoric acid having the formula: 
     
       
           H   m+2   P   m   O   3m+1   (I) 
       
     
     Pyro/polyphosphate selected from the group consisting of metal pyrophosphates, metal polyphosphates, metal acid pyrophosphates, metal acid polyphosphates, and mixtures thereof. Preferably the pyro/polyphosphate has the formula (I): 
     
       
           M   z   x   H   y   P   n   O   3n+1   (I) 
       
     
     wherein M is a metal, x is a number from 1 to 12, y is a number from 0 to 12, n is a number from 2 to 10, z is a number from 1 to 5 and the sum of (xz)+y is equal to n+2. M is preferably a Group IA, IIA, IB or IIB metal and more preferably sodium or potassium. These compounds include, for example, pyrophosphates of the formula Na 3 HP 2 O 7 ; K 2 H 2 P 2 O 7 ; Na 3 H 2 P 2 O 10 ; KNaH 2 P 2 O 7  and Na 2 H 2 P 2 O 7  or sodium hexameta phosphate, Na 8 P 6 O 19 . Typically, the metal pyro/polyphosphates are hydrates and may be in powder form. Sodium acid pyrophosphate is the most preferred. 
     Other phosphorus containing compositions include the organic esters of phosphinic and phosphonic acids having the following general formula:                           
     wherein each Q represents the same or different radicals including hydrocarbon radicals such as alkyl, cycloalkyl, aryl, alkyl substituted aryl and aryl substituted alkyl, halogen; hydrogen and combinations thereof provided that at least one Q is an organic radical. Typical examples of phosphates include triphenyl phosphene oxide, phenylbis-dodecyl phosphate, phenylbisneopentyl phosphate, phenylethylene hydrogen phosphate. 
     The phosphorus component is present in the flame retarded molding compositions in an amount effective to enhance the flame retardancy but not in such amount that other essential properties of the molding composition are substantially degraded. Typical amounts are from about 0.02 to about 5, preferably from about 0.2 to about 2 percent and more preferably from about 0.2 to about 1 percent of the phosphorous containing component calculated as atomic phosphorus. 
     Other ingredients employed in low amounts, typically less than 5 percent by weight of the total composition, include stabilizers, lubricants, colorants, plasticizers, nucleants, antioxidants and UV absorbers. These ingredients should be selected so as not to deleteriously affect the desired properties of the molded resin. 
     Although it is not essential, best results are obtained if the ingredients are precompounded, pelletized and then molded. Precompounding can be carried out in conventional equipment. For example, after predrying the polyester resin, other ingredients, and, optionally, other additives and/or reinforcements, a single screw extruder is fed with a dry blend of the composition. On the other hand, a twin screw extrusion machine can be fed with resins and additives at the feed port and reinforcement down stream. 
     Portions of the blend can be precompounded and then, extruded with the remainder of the formulation, and cut or chopped into molding compounds, such as conventional granules, pellets, etc. by standard techniques. 
     Distinct and secure marking can be carried out on the resin compositions of the present invention by means of laser irradiation. 
    
    
     EXAMPLES 
     The formulations shown below were preblended and extruded on a intermeshing-corotating twin-screw extruder at a die head temperature of 250° C. The extrudate was cooled through a water bath prior to pelletizing. Test parts were injection molded on an Engel 35T injection molding machine with a set temperature of approximately 240-260 ° C. The resin was dried for 2-4 hours at 120 ° C. in a forced air circulating oven prior to injection molding. 
     The formulation of the Examples are particularly useful with a Nd:YAG type laser. 
     In the Examples the Cu-fumarate laser marking agent was utilized. 
     
       
         
               
             
               
               
             
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Examples of the Invention. Laser marking contrast as measured 
               
               
                 on squares of 10 × 10 mm vs. laser marking speed Nd:YAG laser 1064/532 nm 
               
               
                 Carl Baasel laser Settings: 1064 nm, Examples 1-4 at 16A/5000 Hz and 
               
               
                 Examples 5-8 at 18A/5000 Hz, Modeblender = 1.6 
               
             
          
           
               
                   
                 Amperage Laser (A) 
               
             
          
           
               
                 Composition 
                 16A 
                 18A 
               
               
                   
               
             
          
           
               
                   
                 Example 1 = 
                   
                   
                   
                 Example 5 = 
                   
                   
                   
               
               
                   
                 reference 
                 Example 2 
                 Example 3 
                 Example 4 
                 reference 
                 Example 6 
                 Example 7 
                 Example 8 
               
               
                   
               
               
                 Polyester *   
                 100% 
                 99.50% 
                 99% 
                 98% 
                 100% 
                 99.50% 
                 99% 
                 98% 
               
               
                 Cu-fumarate 
                   
                 0.50% 
                 1% 
                 2% 
                   
                 0.50% 
                 1% 
                 2% 
               
               
                   
               
               
                 Laser marking 
                 Y-value **   
                 Y-value 
                 Y-value 
                 Y-value 
                 Y-value 
                 Y-value 
                 Y-value 
                 Y-value 
               
               
                 results 
               
               
                   
               
               
                 background 
                 73.6 
                 49.7 
                 44.4 
                 36.5 
                 73.6 
                 49.7 
                 44.4 
                 36.5 
               
               
                 Speed 500 mm/s 
                 57.5 
                 13.2 
                 12.4 
                 10.0 
                 20.7 
                 10.5 
                 8.8 
                 8.6 
               
               
                 Speed 750 mm/s 
                 69.6 
                 13.8 
                 12.4 
                 11.5 
                 53.7 
                 12.4 
                 11.2 
                 9.3 
               
               
                 Speed 999 mm/s 
                 70.5 
                 18.0 
                 14.3 
                 12.7 
                 63.4 
                 12.7 
                 12.4 
                 11.1 
               
               
                   
               
               
                   
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
               
               
                   
                 Ratio ***   
                 Ratio 
                 Ratio 
                 Ratio 
                 Ratio 
                 Ratio 
                 Ratio 
                 Ratio 
               
               
                   
               
               
                 Speed 500 mm/s 
                 1.28 
                 3.77 
                 3.58 
                 3.65 
                 3.56 
                 4.73 
                 5.05 
                 4.24 
               
               
                 Speed 750 mm/s 
                 1.05 
                 3.60 
                 3.60 
                 3.17 
                 1.37 
                 4.01 
                 3.96 
                 3.92 
               
               
                 Speed 999 mm/s 
                 1.04 
                 2.76 
                 3.10 
                 2.87 
                 1.16 
                 3.91 
                 3.58 
                 3.29 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Pigmented Examples. Laser marking contrast as measured on 
               
               
                 laser marked squares of 10 × 10 mm. Laser: Nd:YAG 1064/532 nm 
               
               
                 Carl Baasel laser, Settings: 1064 nm, 16A/5000 Hz and modeblender 1.6 
               
             
          
           
               
                 Compo- 
                 Example 1 = 
                   
                   
                 Example 4 = 
                   
               
               
                 sition 
                 reference 
                 Example 2 
                 Example 3 
                 reference 
                 Example 5 
               
               
                   
               
             
          
           
               
                 Poly- 
                 97.00% 
                 96.50% 
                 95.00% 
                 98.2475% 
                 96.9975% 
               
               
                 ester* 
               
               
                 Cu- 
                   
                 0.50% 
                 2.00% 
                   
                 1.2500% 
               
               
                 fum- 
               
               
                 arate 
               
               
                 TiO 2   
                 3.00% 
                 3.00% 
                 3.00% 
                 1.7500% 
                 1.7500% 
               
               
                 Carbon 
                   
                   
                   
                 0.0025% 
                 0.0025% 
               
               
                 black 
               
               
                 Laser 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
                 Contrast 
               
               
                 marking 
                 Ratio*** 
                 Ratio 
                 Ratio 
                 Ratio 
                 Ratio 
               
               
                 results 
               
               
                 speed 
                 2.6 
                 3.0 
                 3.4 
                 2.3 
                 3.1 
               
               
                 800 
               
               
                 mm/s 
               
               
                 speed 
                 2.6 
                 2.8 
                 2.9 
                 2.5 
                 2.7 
               
               
                 999 
               
               
                 mm/s 
               
               
                   
               
               
                 *Polyester used was Valox ® polyester resin grade 325M-1001, natural 325M, no color pigments added  
               
               
                 **Y-value measured on a photospectrometer according to Cielab Method, DIN 6174, source D65  
               
               
                 ***Contrast ratio (CR) calculated by dividing the Y value of the background color by the Y value of the laser marked area