Patent Publication Number: US-4654272-A

Title: Decreasing the frictional sounds of non-olefinic synthetic resin materials

Description:
FIELD OF THE INVENTION 
     This invention relates to frictional sound-lowering agents to control frictional sounds produced when molded articles, particularly interior parts for automobiles, consisting of non-olefinic series resins such as PVC and ABS are contacted with each other. 
     DESCRIPTION OF THE PRIOR ART 
     Non-olefinic series resins such as PVC and ABS which have good appearance and nice touch when molded are frequently used for the interior parts of automobiles. Parts are sometimes molded from olefinic-series resins but these resins cannot provide the wettish touch that is provided by non-olefinic series resins because of their waxlike or eraserlike surface state. 
     However, when parts molded from non-olefinic series resins are placed in contact with each other, frictional squeaky sounds are produced which can make driving uncomfortable. It is believed that these frictional sounds result from a &#34;Stick-Slip&#34; phenomenon wherein the sounds are caused by each resin material being extended by friction and then contracting by separation of the ultimate extension. In other words, although the frictional resistance values between the parts depend on conditions of the parts such as temperature, pressure, hardness, velocity, material quality, and surface structure, the frictional resistance can produce irritating sounds when there is a large difference between the coefficient of static friction and that of kinematic friction. 
     In order to decrease these frictional sounds, various methods have been disclosed including placing a slip tape, e.g., Teflon tape, on the surface of the parts as described in Japanese Laid-Open Patent Publication No. 47-12614 published Oct. 14, 1972, the placing of buffer materials such as urethane slabs and unwoven cloth between the parts, and the applying of a lubricant, e.g., silicone, on the surface of the parts. However, the slip tape and buffer materials are not suitable because they not only require much labor and time for application thereof but they cannot be applied to parts having complicated surface structures and may worsen the appearance. The lubricants are sticky and easily removed from the surface by friction. 
     An object of this invention is to provide frictional sound-lowering agents for resin materials used for molded parts for automobiles and, more particularly, agents which decrease the production of frictional sounds by decreasing the difference between the coefficient of static friction and that of kinematic friction in parts molded from non-olefinic series resins. 
     SUMMARY OF THE INVENTION 
     According to the present invention, an amide stearate or a derivative thereof is combined with non-olefinic series synthetic resins such as PVC and ABS in molded parts for automobiles, or a paint containing an amide stearate or a derivative thereof is applied to the surface of a part molded from a non-olefinic series resin material to decrease the difference between the coefficient of static friction and the coefficient of kinematic friction obtained when the molded parts are contacted with each other. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     The interior parts for cars which are molded from synthetic resins according to the present invention include sheetlike parts such as inner panel surface leather, door surface leather, roof surface leather, garnish, change lever boots, and sun visors; and rim components such as opening trim, quarter trim, FR roof trim, and rear roof trim. These parts are typically formed from non-olefinic series resins such as PVC (polyvinylchloride) and ABS (acrylonitrile-butadiene-styrene copolymer). 
     The non-olefinic series resins can be molded into interior parts for cars after a frictional sound-lowering agent containing an amide stearate and/or a derivative thereof as an effective component is kneaded therein. 
     In addition to the frictional sound-lowering agent, various conventional components of molded parts for automobiles including plasticizer, stabilizers, fillers and other additives, can be combined with the non-olefinic series resin. These materials are used in conventional amounts as will be understood by persons of ordinary skill in the art. Sample formulations for molded parts for automobiles are shown in Table 1. 
     The amide stearate or derivative thereof is used in an amount of at least 0.7 part per 100 parts by weight of the non-olefinic synthetic resin. When the frictional sound-lowering agent is used in an amount of less than 0.7 part per 100 parts of the resin, heat bleeding initially lowers frictional sounds but there is a problem as to durability. On the other hand, an excessive amount of the frictional sound-lowering agent bleeds excessively and gives the molded article an appearance of being powdered on the surface. Therefore, the amount of the agent combined with the synthetic resin should be more than 0.7 part but less than about 10 parts per 100 parts resin. 
     
                       TABLE 1                                                     
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Component                                                                 
(parts by                                                                 
weight) Example 1            Example 2                                    
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Resin   PVC           100                                                 
        (molecular weight                                                 
        1100)                                                             
Plasticizer                                                               
        DIDP          50-75                                               
        Epoxidated soy                                                    
                      2-3                                                 
        bean oil                                                          
Stabilizer                                                                
        Stearate Ba/Zn                                                    
                      0.7-0.9                                             
        Diphenyl octyl                                                    
                      slightly                                            
        phosphite                                                         
Additives                                                                 
        Sb.sub.2 O.sub.3                                                  
                      1-3                                                 
Filler  CaCO.sub.3    20-25                                               
Frictional                                                                
        Bisamide stearate                                                 
                      0.7 or more                                         
                                 Ethylene bis-                            
sound-                           amide hydroxy-                           
lowering                         stearate                                 
agent                            0.7 or more                              
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     In another embodiment according to the present invention, the frictional sound-lowering agent may be applied to the surface of an interior part for an automobile that has been molded from a non-olefinic series resin in the form of a coating or paint. As the coating or paint, there can be used any material which provides a vehicle for applying the amide stearate or derivative to the surface of the molded article and which will not deleteriously affect the appearance of the surface. For example, coatings such as those described in Table 2 can be used. 
     These coatings are applied to the surface of interior parts for cars with a spray coater or a bar coater. 
     To determine the effect of using an amide stearate according to the present invention as a frictional sound-lowering agent, molded parts for cars produced by combining the frictional sound-lowering agents with the non-olefinic synthetic resin or by coating parts molded from a non-olefinic synthetic resin with a coating containing the agents were rubbed against each other. The frictional sound produced by rubbing the parts together was measured with a noise-measuring instrument A range at a distance of 10 cm away from the parts. The results are shown in Tables 3 and 4. It is to be noted that the background noise level obtained before measuring the frictional sounds, namely in the blank test, was 50-51 dB. 
     
                                           TABLE 2                                 
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Component                                                                 
      Example 1        Example 2                                          
                             Example 3                                    
                                   Example 4                              
                                         Example 5                        
                                               Example 6                  
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Resin PVC series                                                          
                5  wt %                                                   
                       ←                                             
                             Acrylic                                      
                                   ←                                 
                                         Acrylic                          
                                               ←                     
                             resins      polyester                        
                                         copolymer                        
Delustering                                                               
      Silica    1.0                                                       
                   wt %                                                   
                       ←                                             
                             ←                                       
                                   ←                                 
                                         ←                           
                                               ←                     
Agent PE        1.5                                                       
                   wt %                                                   
Stabilizer                                                                
      Modified  3.0                                                       
                   wt %                                                   
                       ←                                             
                             ←                                       
                                   ←                                 
                                         ←                           
                                               ←                     
      epoxy                                                               
      Chelator  0.5                                                       
                   wt %                                                   
      Stearate Ba/Zn                                                      
                1.0                                                       
                   wt %                                                   
      Organic tin maleate                                                 
                2.0                                                       
                   wt %                                                   
Solvent                                                                   
      Toluene   82 wt %                                                   
      MEK       82 wt %                                                   
      Cyclohexane                                                         
                82 wt %                                                   
                       ←                                             
                             ←                                       
                                   ←                                 
                                         ←                           
                                               ←                     
Frictional                                                                
      Ethylene bisamide                                                   
                2-4                                                       
                   wt %                                                   
                       Bisamide                                           
                             Ethylene                                     
                                   Bisamide                               
                                         Ethylene                         
                                               Bisamide                   
sound-                                                                    
      hydroxystearate  stearate                                           
                             bisamide                                     
                                   stearate                               
                                         bisamide                         
                                               stearate                   
lowering               2-4 wt %                                           
                             hydroxy-                                     
                                   2-4 wt %                               
                                         hydroxy-                         
                                               2-4 wt %                   
agent                        stearate    stearate                         
                             2-4 wt %    2-4 wt %                         
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                       TABLE 3                                                     
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Frictional Sound-Lowering Agent (Bisamide Stearate)                       
Combined with the Synthetic Resin                                         
                    Soft     Soft    Soft                                 
       Soft         PVC +    PVC +   PVC +                                
       PVC   ABS    0.7%     1.0%    2.0%                                 
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Soft PVC 80 dB   82     52     52      52                                 
Soft PVC +                                                                
         53      54     53     --      --                                 
0.7%*                                                                     
Soft PVC +                                                                
         52      54     --     52      --                                 
1.0%                                                                      
Soft PVC 52      51     --     --      53                                 
+2.0%                                                                     
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 *The amount of the frictional soundlowering agent is based on the weight 
 of the synthetic resin.                                                  
 
    
     
                       TABLE 4                                                     
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Molded Article Coated with the Frictional                                 
Sound-Lowering Agent (Bisamide Stearate)                                  
       Soft            Soft PVC + Soft PVC +                              
       PVC     ABS     2.0%       4.0%                                    
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Soft PVC 80 dB     82      52       52                                    
Soft PVC +                                                                
         53        51      52       52                                    
2.0%                                                                      
Soft PVC +                                                                
         52        51      52       52                                    
4.0%                                                                      
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     As clearly shown in Tables 3 and 4, it has been found that an amide stearate and/or a derivative thereof can decrease the production of the frictional sounds caused when molded articles are rubbed against one another. The frictional sound-lowering agents of this invention can effectively decrease the frictional sounds without any problems relating to stickiness and durability such as that caused when a lubricant is used and without the difficulties of inserting slip tapes, urethane slabs and unwoven cloths in complicated surface structures.