Patent Description:
Reinforcing fibers can be used to alter the physical properties of a given thermoplastic resin. Depending upon the base resin profile, these fillers can improve certain physical properties of a given polymer composition. Conventional glass-fiber fillers, however, may negatively affect impact properties (such as ductility) and flame retardance of the thermoplastic resin after use in certain manufacturing processes.

These and other shortcomings are addressed by aspects of the present disclosure. <CIT> discloses a glass fiber-reinforced polycarbonate resin composition comprising <NUM> pts. resin component containing polycarbonate polydiorganosiloxane copolymer resin (a1) and aromatic polycarbonate resin (a2), <NUM>-<NUM> pts- wt. flat cross-section glass fiber, <NUM>-<NUM> pts. adhesive improving agent, <NUM>-<NUM> pts. phosphorus-based retarder and <NUM>-<NUM> pts. fluorine-containing dripping inhibiting agent.

The present invention relates to a composition comprising: a polymer base resin; from <NUM> wt. % to <NUM> wt. % of a fiber filler comprising a sizing component comprising a sizing agent and a reactive aid comprising a diisocyanate compound which comprises hexamethylene diisocyanate, wherein the sizing component is present as a coating on the fiber filler, and wherein the sizing component is present in an amount of from <NUM> wt. % to <NUM> wt. % based on the weight of the fiber filler, and the reactive aid comprising the diisocyanate compound is present in an amount of from <NUM> wt. % to <NUM> wt. % based on the weight of the sizing component; and an additive.

The drawings illustrate generally, by way of example, but not by way of limitation, various aspects discussed in the present document.

Amorphous resins, such as polycarbonate, have good ductility and very low shrinkage making them desirable for use in the consumer electronics market. Various applications in the field may require high modulus and ductility performance. The performance of fiber filled composition can be a function of many different factors. Fibrous fillers, such as glass fiber, carbon fiber, or basalt fiber, are often in high loadings to provide high modulus to the amorphous resin. However, the fiber may negatively affect ductility and impact strength. Compositions of the present disclosure demonstrate that the strength of fiber filled material may highly depend on the interphase (coupling or connection) between a polymer resin and reinforcing fiber. The present invention relates to a composition comprising a polymer base resin, a fiber filler comprising a sizing component, and an additive as claimed in the appended claims. The compositions of the present disclosure may provide filled thermoplastic compositions exhibiting good mechanical performance (particularly, ductility), and good flame retardancy.

The disclosed composition may exhibit a notched Izod impact strength of <NUM> J/m to <NUM> J/m and an unnotched impact strength of <NUM> J/m to <NUM> J/m when tested in accordance with D256.

Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that they are not limited to specific synthetic methods unless otherwise specified, or to particular reagents unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The disclosed thermoplastic compositions include a polymeric base resin. In some aspects the polymeric base resin includes polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyamide (PA), polycarbonate (PC), poly(p-phenylene oxide) (PPO), or combinations of one or more of these polymers. In particular aspects the polymeric base resin may include PC, PC copolymers, PBT, PET and PC, PA, PO, or PA and PPO. The polymer base resin may have certain functional moieties that promote interaction with the sized fiber filler of the present disclosure. For example, the polymer base resin may have functional moieties such as hydroxyl, carboxyl, thiol, amine, and epoxy.

As used herein, polybutylene terephthalate can be used interchangeably with poly(<NUM>,<NUM>-butylene terephthalate). Polybutylene terephthalate is one type of polyester. Polyesters, which include poly(alkylene dicarboxylates), liquid crystalline polyesters, and polyester copolymers, can be useful in the disclosed thermoplastic compositions of the present disclosure.

Polyesters have repeating units of the following formula (A):
<CHM>
wherein T is a residue derived from a terephthalic acid or chemical equivalent thereof, and D is a residue derived from polymerization of an ethylene glycol, butylene diol, specifically <NUM>,<NUM>-butane diol, or chemical equivalent thereof. Chemical equivalents of diacids include dialkyl esters, e.g., dimethyl esters, diaryl esters, anhydrides, salts, acid chlorides, and acid bromides. Chemical equivalents of ethylene diol and butylene diol include esters, such as dialkylesters and diaryl esters.

In addition to units derived from a terephthalic acid or chemical equivalent thereof, and ethylene glycol or a butylene diol, specifically <NUM>,<NUM>-butane diol, or chemical equivalent thereof, other T and/or D units can be present in the polyester, provided that the type or amount of such units do not significantly adversely affect the desired properties of the thermoplastic compositions.

Examples of aromatic dicarboxylic acids include <NUM>,<NUM>-naphthalenedicarboxylic acid, <NUM>,<NUM>-naphthalenedicarboxylic acid, <NUM>,<NUM>-naphthalenedicarboxylic acid, and combinations comprising at least one of the foregoing dicarboxylic acids. Exemplary cycloaliphatic dicarboxylic acids include norborene dicarboxylic acids and <NUM>,<NUM>-cyclohexanedicarboxylic acids. In a specific aspect, T is derived from a combination of terephthalic acid and isophthalic acid wherein the weight ratio of terephthalic acid to isophthalic acid is <NUM>:<NUM> to <NUM>:<NUM> (or about <NUM>:<NUM> to about <NUM>:<NUM>), specifically <NUM>:<NUM> to <NUM>:<NUM> (or about <NUM>:<NUM> to about <NUM>:<NUM>).

Examples of C6-C12 aromatic diols include, but are not limited to, resorcinol, hydroquinone, and pyrocatechol, as well as diols such as <NUM>,<NUM>-naphthalene diol, <NUM>,<NUM>-naphthalene diol, <NUM>,<NUM>-naphthalene diol, <NUM>,<NUM>'-dihydroxybiphenyl, bis(<NUM>-hydroxyphenyl)ether, bis(<NUM>-hydroxyphenyl)sulfone, and combinations comprising at least one of the foregoing aromatic diols.

Exemplary C2-C12 aliphatic diols include, but are not limited to, straight chain, branched, or cycloaliphatic alkane diols such as propylene glycol, i.e., <NUM>,<NUM>- and <NUM>,<NUM>-propylene glycol, <NUM>,<NUM>-dimethyl-<NUM>,<NUM>-propane diol, <NUM>-ethyl-<NUM>-methyl-<NUM>,<NUM>-propane diol, <NUM>,<NUM>-but-<NUM>-ene diol, <NUM>,<NUM>- and <NUM>,<NUM>-pentane diol, dipropylene glycol, <NUM>-methyl-<NUM>,<NUM>-pentane diol, <NUM>,<NUM>-hexane diol, dimethanol decalin, dimethanol bicyclooctane, <NUM>,<NUM>-cyclohexane dimethanol, including its cis- and trans-isomers, triethylene glycol, <NUM>,<NUM>-decanediol; and combinations comprising at least of the foregoing diols.

In another aspect, the compositions of the present disclosure can include polyesters including, for example, aromatic polyesters, poly(alkylene esters) including poly(alkylene arylates), and poly(cycloalkylene diesters). Aromatic polyesters can have a polyester structure according to formula (A), wherein D and T are each aromatic groups as described hereinabove. In an aspect, useful aromatic polyesters can include, for example, poly(isophthalate-terephthalate-resorcinol)esters, poly(isophthalate-terephthalate-bisphenol A)esters, poly[(isophthalate-terephthalate-resorcinol)ester-co-(isophthalate-terephthalate-bisphenol A)]ester, or a combination comprising at least one of these. Also contemplated are aromatic polyesters with a minor amount, e.g., about <NUM> to about <NUM> wt. %, based on the total weight of the polyester, of units derived from an aliphatic diacid and/or an aliphatic polyol to make copolyesters. Poly(alkylene arylates) can have a polyester structure according to formula (A), wherein T comprises groups derived from aromatic dicarboxylates, cycloaliphatic dicarboxylic acids, or derivatives thereof.

Examples of specifically useful T groups include, but are not limited to, <NUM>,<NUM>-, <NUM>,<NUM>-, and <NUM>,<NUM>-phenylene; <NUM>,<NUM>- and <NUM>,<NUM>-naphthylenes; cis- or trans-<NUM>,<NUM>-cyclohexylene. Specifically, where T is <NUM>,<NUM>-phenylene, the poly(alkylene arylate) is a poly(alkylene terephthalate). In addition, for poly(alkylene arylate), specifically useful alkylene groups D include, for example, ethylene, <NUM>,<NUM>-butylene, and bis-(alkylene-disubstituted cyclohexane) including cis- and/or trans-<NUM>,<NUM>-(cyclohexylene)dimethylene.

Examples of poly(alkylene terephthalates) include poly(ethylene terephthalate) (PET), poly(<NUM>,<NUM>-butylene terephthalate) (PBT), and poly(propylene terephthalate) (PPT). Also useful are poly(alkylene naphthoates), such as poly(ethylene naphthanoate) (PEN), and poly(butylene naphthanoate) (PBN). A useful poly(cycloalkylene diester) is poly(cyclohexanedimethylene terephthalate) (PCT). Combinations including at least one of the foregoing polyesters can also be used.

Copolymers including alkylene terephthalate repeating ester units with other ester groups can also be useful. Useful ester units can include different alkylene terephthalate units, which can be present in the polymer chain as individual units, or as blocks of poly(alkylene terephthalates). Specific examples of such copolymers include poly(cyclohexanedimethylene terephthalate)-co-poly(ethylene terephthalate), abbreviated as PETG where the polymer includes greater than or equal to <NUM> mol % of poly(ethylene terephthalate), and abbreviated as PCTG where the polymer comprises greater than <NUM> mol % of poly(<NUM>,<NUM>-cyclohexanedimethylene terephthalate).

Poly(cycloalkylene diester)s can also include poly(alkylene cyclohexanedicarboxylate)s. Of these, a specific example is poly(<NUM>,<NUM>-cyclohexanedimethanol-<NUM>,<NUM>-cyclohexanedicarboxylate) (PCCD), having recurring units of formula (B):
<CHM>
wherein, as described using formula (A), D is a <NUM>,<NUM>-cyclohexanedimethylene group derived from <NUM>,<NUM>-cyclohexanedimethanol, and T is a cyclohexane ring derived from cyclohexanedicarboxylate or a chemical equivalent thereof, and can comprise the cis-isomer, the trans-isomer, or a combination comprising at least one of the foregoing isomers.

Polyesters, including polybutylene terephthalate, can be obtained by interfacial polymerization or melt-process condensation as described above, by solution phase condensation, or by transesterification polymerization wherein, for example, a dialkyl ester such as dimethyl terephthalate can be transesterified with ethylene glycol using acid catalysis, to generate poly(ethylene terephthalate). The condensation reaction may be facilitated by the use of a catalyst, with the choice of catalyst being determined by the nature of the reactants. The various catalysts for use herein are very well known in the art and are too numerous to mention individually herein. Generally, however, when an alkyl ester of the dicarboxylic acid compound is employed, an ester interchange type of catalyst is preferred, such as Ti(OC<NUM>H<NUM>)<NUM> in n-butanol.

It is 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 sometime desirable to have various concentrations of acid and hydroxyl end groups on the polyester, depending on the ultimate end use of the composition.

In another aspect, the composition can further comprise poly(<NUM>,<NUM>-butylene terephthalate) or "PBT" resin. PBT can be obtained by polymerizing a glycol component of which at least <NUM> mol %, preferably at least <NUM> mol %, consists of tetramethylene glycol and an acid or ester component of which at least <NUM> mol %, preferably at least <NUM> mol %, consists of terephthalic acid and/or polyester-forming derivatives therefore. Commercial examples of PBT include those available under the trade names VALOX™ <NUM>, VALOX™ <NUM> and VALOX™ <NUM>, manufactured by SABIC™, having an intrinsic viscosity of <NUM> deciliters per gram (dl/g) to about <NUM> dl/g (or <NUM> dl/g to <NUM> dl/g) as measured in a <NUM>:<NUM> phenol/tetrachloroethane mixture or similar solvent at <NUM> degrees Celsius (°C) to <NUM>° C. In one aspect, the PBT resin has an intrinsic viscosity of <NUM> dl/g to <NUM> dl/g (or about <NUM> dl/g to about <NUM> dl/g), specifically <NUM> dl/g to <NUM> dl/g (or about <NUM> dl/g to about <NUM> dl/g).

As used herein, poly(p-phenylene oxide) can be used interchangeably with poly(p-phenylene ether) or poly (<NUM>,<NUM> dimethyl-p-phenylene oxide). Poly(p-phenylene oxide) may be included by itself or may be blended with other polymers, including but not limited to polystyrene, high impact styrene-butadiene copolymer and/or polyamide.

As used herein, polycarbonate refers to an oligomer or polymer comprising residues of one or more dihydroxy compounds, e.g., dihydroxy aromatic compounds, joined by carbonate linkages; it also encompasses homopolycarbonates, copolycarbonates, and (co)polyester carbonates. Polycarbonates, and combinations comprising thereof, may also be used as the polymer base resin. As used herein, "polycarbonate" refers to an oligomer or polymer comprising residues of one or more dihydroxy compounds, e.g., dihydroxy aromatic compounds, joined by carbonate linkages; it also encompasses homopolycarbonates, copolycarbonates, and (co)polyester carbonates. The terms "residues" and "structural units", used in reference to the constituents of the polymers, are synonymous throughout the specification. In certain aspects the polycarbonate polymer is a Bisphenol-A polycarbonate, a high molecular weight (Mw) high flow/ductile (HFD) polycarbonate, a low Mw HFD polycarbonate, or a combination thereof.

The terms "BisA," "BPA," or "bisphenol A," which can be used interchangeably, as used herein refers to a compound having a structure represented by formula (C):
<CHM>.

BisA can also be referred to by the name <NUM>,<NUM>'-(propane-<NUM>,<NUM>-diyl)diphenol; p,p'-isopropylidenebisphenol; or <NUM>,<NUM>-bis(<NUM>-hydroxyphenyl)propane. BisA has the <NPL>.

In addition to the polycarbonates described above, combinations of the polycarbonate with other thermoplastic polymers, for example combinations of homopolycarbonates, copolycarbonates, and polycarbonate copolymers with polyesters, can be used. For example, useful polyesters include, but are not limited to, poly(alkylene dicarboxylates), liquid crystalline polyesters, and polyester copolymers as described herein. The polyesters described herein can generally be completely miscible with the polycarbonates when blended.

In a specific example, the polycarbonate is a copolymer. The copolymer may comprise repeating units derived from BPA. In yet a further example, the copolymer comprises repeating units derived from sebacic acid. More specifically, the copolymer may comprise repeating units derived from sebacic acid and BPA. Useful polycarbonate copolymers are commercially available and include, but are not limited to, those marketed under the trade names LEXAN™ EXL and LEXAN™ HFD polymers available from SABIC™.

In further aspects, the polymeric base resin may comprise a polycarbonate-polysiloxane copolymer. Non-limiting examples of polycarbonate-polysiloxane copolymers may comprise various copolymers available from SABIC. In an aspect, the polysiloxane-polycarbonate copolymer can contain <NUM> % by weight polysiloxane content based upon the total weight of the polysiloxane-polycarbonate copolymer. In various aspects, the <NUM> % by weight polysiloxane block copolymer can have a weight average molecular weight (Mw) of from about <NUM>,<NUM> to <NUM>,<NUM> Daltons using gel permeation chromatography with a bisphenol A polycarbonate absolute molecular weight standard. In certain aspects, the <NUM>% weight siloxane polysiloxane-polycarbonate copolymer can have a melt volume flow rate (MVR) of about <NUM> cubic centimeters per <NUM> minutes (cm<NUM>/ <NUM>) at <NUM> /<NUM> kilogram (kg) (see for example, C9030T, a <NUM> % by weight polysiloxane content copolymer available from SABIC™ as "transparent" EXL C9030T resin polymer). In another example, the polysiloxane-polycarbonate block can comprise <NUM> % by weight polysiloxane based upon the total weight of the polysiloxane block copolymer. For example, an appropriate polysiloxane-polycarbonate copolymer can be a bisphenol A polysiloxane-polycarbonate copolymer endcapped with para-cumyl phenol (PCP) and having a <NUM> % polysiloxane content (see C9030P, commercially available from SABIC™ as the "opaque" EXL C9030P). In various aspects, the weight average molecular weight of the <NUM> % polysiloxane block copolymer can be about <NUM>,<NUM> Daltons to about <NUM>,<NUM> Daltons when tested according to a polycarbonate standard using gel permeation chromatography (GPC) on a cross-linked styrenedivinylbenzene column and calibrated to polycarbonate references using a UV-VIS detector set at <NUM> nanometer (nm) on <NUM> milligram per milliliter (mg/ml) samples eluted at a flow rate of about <NUM>/minute. Moreover, the <NUM>% polysiloxane block copolymer can have an MVR at <NUM>/<NUM> of <NUM><NUM>/ <NUM> and can exhibit siloxane domains sized in a range of from about <NUM> micron to about <NUM> micrometers (microns, µm).

As used herein, a polyamide is a polymer having repeating units linked by amide bonds, and can include aliphatic polyamides (PA) (e.g., the various forms of nylon such as nylon <NUM> (PA6), nylon <NUM> (PA66) and nylon <NUM> (PA9)), polyphthalamides (e.g., PPA/high performance polyamide) and aramides (e.g., para-aramid and meta-aramid).

In a further aspect, the polymeric base resin can have a weight average molecular weight from <NUM>,<NUM> Daltons to <NUM>,<NUM> Daltons, or from about <NUM>,<NUM> Daltons to about <NUM>,<NUM> Daltons.

A mixture of polymeric base resins with differing viscosities can be used to make a blend of two or more polymeric base resins to allow for control of viscosity of the final thermoplastic composition.

In some aspects, the polymer base resin can be present in the thermoplastic composition in an amount from about <NUM> wt. % to about <NUM> wt. In other aspects, the polymeric base resin can be present in an amount from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt.

The disclosed thermoplastic compositions comprise a fiber filler. The fiber filler has a sizing component as a coating such that the fiber filler may be referred to as sized fiber filler. The sizing component may be selected for compatibility with the polymeric base resin. The sizing component comprises a sizing agent and a reactive aid. The sizing component may facilitate wet-out and wet-through of the polymer base resin upon the fiber strands and assists in attaining desired physical properties in the thermoplastic composition.

Suitable fibers include, for example, glass fibers, carbon fibers, basalt fibers, polymeric fibers, metallic fibers, and mineral (ceramic, inorganic) fibers. Glass fibers (fiberglass) may be any type of glass, e.g., A glass, E glass, S glass, or D glass. Carbon fibers (which include graphite fibers) are typically prepared by pyrolysis of organic or polymeric fibers (such as PAN). Polymeric fibers include fibers made from any of the known types of thermoplastic polymers such as polyamides, polyolefins, polyaramids, polyesters, and poly(p-phenylene-<NUM>,<NUM>-benzobisoxazoIe)(PBO). Suitable metallic fibers include fibers prepared using any type of metal or metal alloy, such as iron, steel, aluminum, aluminum alloys, copper, titanium, nickel, gold, and silver. Mineral fibers that can be used in the present disclosure are fibers made from natural or synthetic minerals, refractory oxides or metal oxides and include, but are not limited to, mineral wool, rock wool, stone wool, basalt fibers, alumina fibers, beryllia fibers, magnesia fibers, thoria fibers, zirconia fibers, silicon carbide fibers, quartz fibers, boron fibers, asbestos fibers and high silica fibers. In specific examples, the fiber is glass fiber. In further examples, the fiber is carbon fiber. In yet further examples, the fiber is basalt fiber.

The fiber filler may comprise glass fiber, carbon fiber, basalt fiber, or a combination thereof. A fiber filler such as glass fiber, carbon fiber, or basalt fiber may be sized with the sizing component. In certain examples, the fiber filler comprises a glass fiber.

A glass fiber may be selected from E-glass, S-glass, AR-glass, T-glass, D-glass R-glass, and combinations thereof. In a still further aspect, the glass fiber is one or more S-glass materials. High-strength glass is generally known as S-type glass in the United States, R-glass in Europe and T-glass in Japan. High-strength glass has appreciably higher amounts of silica oxide, aluminum oxide and magnesium oxide than E-glass. S-<NUM> glass is approximately <NUM>-<NUM>% stronger than E-glass. The glass fibers can be made by standard processes, e.g., by steam or air blowing, flame blowing, and mechanical pulling. Exemplary glass fibers for thermoplastic compositions of the present disclosure may be made by mechanical pulling. One purely exemplary glass fiber suitable for use in the glass fiber component in an aspect of the disclosure is an E-glass fiber ECS303H, available from Chongqing Polycomp International Corp.

In a further aspect, the glass fiber can be continuous or chopped. In a still further aspect, the glass fiber is continuous. In yet a further aspect, the glass fiber is chopped. Glass fibers in the form of chopped strands may have a length of <NUM> millimeter (mm) to <NUM> centimeters (cm) or about <NUM> to about <NUM>, specifically <NUM> millimeter (mm) to <NUM> or about <NUM> to about <NUM>, and more specifically <NUM> to <NUM>, or about <NUM> millimeter to about <NUM> centimeters. In various further aspects, the glass fiber has a length from <NUM> to <NUM> or about <NUM> to about <NUM>. In a yet further aspect, the glass fiber has a length from <NUM> to <NUM>, or from about <NUM> to about <NUM>. In an even further aspect, the glass fiber has a length from <NUM> to <NUM>, or from about <NUM> to about <NUM>.

In various further aspects, the glass fiber has a round (or circular), flat, or irregular cross-section. Thus, use of non-round fiber cross sections is possible. In a still further aspect, the glass fiber has a circular cross-section. In yet further aspect, the diameter of the glass fiber is from <NUM> micrometer (micron, µm) to <NUM>, or from about <NUM> to about <NUM>. In an even further aspect, the diameter of the glass fiber is from <NUM> to <NUM> or from about <NUM> to about <NUM>. In a still further aspect, the diameter of the glass fiber is from <NUM> to <NUM> or from about <NUM> to about <NUM>. In a still further aspect, the glass fiber has a diameter from <NUM> to <NUM> or from about <NUM> to about <NUM>.

As provided above, glass fiber having a flat cross-section may be used. A flat glass fiber may have an aspect ratio for the flat cross-section of <NUM> to <NUM> or from about <NUM> to about <NUM>. For example, the flat cross-section glass may have a flat ratio of <NUM>:<NUM>.

The fiber filler is present in an amount from <NUM> wt. % to <NUM> wt. In further aspects, the glass fiber component is present in an amount from <NUM> wt. % to <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. %, or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt.

As provided herein, the fiber filler is sized with a sizing component. The sizing component may improve the interphase between the polymer base resin and the fiber filler. In a further aspect, the sizing component is present in an amount from <NUM> wt. % to <NUM> wt. % based on the weight of the glass fibers.

The sizing component comprises a sizing agent and a reactive aid. The sizing agent may comprise an epoxy resin, a polyurethane resin, a nylon resin, a polypropylene resin, a polyimide resin, phenoxy resin, ethylene/propylene maleic anhydride copolymer resin, or a combination thereof. An exemplary sizing agent may comprise a BPA-epoxy resin.

As provided herein, the sizing component comprises a reactive aid. More specifically, in some examples, the sizing component may comprise a sizing agent modified with an appropriate reactive aid. The reactive aid is present in an amount of from <NUM> wt. % to <NUM> wt. % based on the total weight of the sizing component.

The reactive aid of the sizing component comprises a diisocyanate compound which comprises hexamethylene diisocyanate. The diisocyanate compound may include isophorone diisocyanate and hexamethylene diisocyanate. As an example, the sizing component may comprise a mixture of the diisocyanate and epoxy.

As a further example, the sizing component comprises a BPA-epoxy and a hexamethylene diisocyanate such that the sizing agent comprises the BPA-epoxy and the reactive aid comprises hexamethylene diisocyanate. The foregoing reactive aid example may provide improved properties when compared to a sized fiber in the absence of a reactive aid as shown in the examples provided herein. Moreover, the sized fiber having hexamethylene diisocyanate as the reactive aid may provide even more improved physical properties (such as impact strength) when compared to the sized fiber having only isophorone diisocyanate as the reactive aid.

The improvement in physical properties may be attributed to the interaction of the sizing component with the polymer base resin. More specifically, the sizing agent and reactive aid promote interaction of the fiber filler with the functional endgroups of the polymer base resin.

In preparing the fiber filler, such as the glass fiber filler the strand may be first formed of filaments and then sized. The amount of sizing employed is generally that amount which is sufficient to bind the glass filaments into a continuous fiber strand and ranges from <NUM> to <NUM> wt. % based on the weight of the glass fibers. Generally, this may be <NUM> wt. % or about <NUM> wt. % based on the weight of the glass filament.

The fiber may be in the form of threads, strands, or rovings, at the time it is sized with the sizing component. After sizing, the fibers may be further processed (e.g., into yarns, threads, strands, rovings, mats, meshes, scrims, woven fabric, and non-woven fabric). In one aspect, the fiber is in continuous form (e.g., an unbroken filament, thread, strand or yarn) at the time it is sized, but then converted into discontinuous form by cutting, chopping or other such operation. The discontinuous sized fibers may, for example, be from about <NUM> to about <NUM> in length. The sized fibers may be used, in continuous or discontinuous form, in the manufacture of fiber reinforced composites. Means for applying the sizing composition include, but are not limited to, pads, sprayers, rollers or immersion baths, which allow a substantial amount of the surfaces of the individual filaments of the fiber to be wetted with the sizing composition. The sizing component may be applied to the fibers by dipping, spraying or roll coating. In one example, the sizing component is applied to the fibers continuously.

In addition to the foregoing components, the disclosed thermoplastic compositions include a balance amount of one or more additive materials ordinarily incorporated in thermoplastic compositions of this type, with the proviso that the additives are selected so as to not significantly adversely affect the desired properties of the composition. Combinations of additives can be used. Such additives can be mixed at a suitable time during the mixing of the components for forming the composition. Exemplary and non-limiting examples of additive materials that can be present in the disclosed thermoplastic compositions include one or more of a reinforcing filler, enhancer, acid scavenger, anti-drip agent, antioxidant, antistatic agent, chain extender, colorant (e.g., pigment and/or dye), de-molding agent, flow promoter, flow modifier, lubricant, mold release agent, plasticizer, quenching agent, flame retardant (including for example a thermal stabilizer, a hydrolytic stabilizer, or a light stabilizer), impact modifier, ultraviolet (UV) absorbing additive, UV reflecting additive, UV stabilizer, and laser direct structuring additive.

In an aspect, suitable impact modifiers can include an epoxy-functional block copolymer. The epoxy-functional block copolymer can include units derived from a C<NUM>-<NUM> olefin and units derived from a glycidyl (meth)acrylate. Exemplary olefins include ethylene, propylene, and butylene. The olefin units can be present in the copolymer in the form of blocks, e.g., as polyethylene, polypropylene or polybutylene blocks. It is also possible to use mixtures of olefins, i.e., blocks containing a mixture of ethylene and propylene units, or blocks of polyethylene together with blocks of polypropylene.

In addition to glycidyl (meth)acrylate units, the epoxy-functional block copolymers can further include additional units, for example C<NUM>-<NUM> alkyl (meth)acrylate units. In one aspect, the impact modifier is terpolymeric, comprising polyethylene blocks, methyl acrylate blocks, and glycidyl methacrylate blocks. Specific impact modifiers are a co- or terpolymer including units of ethylene, glycidyl methacrylate (GMA), and methyl acrylate. Suitable impact modifiers include the ethylene-methyl acrylate-glycidyl methacrylate terpolymer comprising <NUM> wt. % or about <NUM> wt. % glycidyl methacrylate units available under the trade name LOTADER™ AX8900 from Arkema. Another epoxy-functional block copolymer that can be used in the composition includes ethylene acrylate, for example an ethylene-ethyl acrylate copolymer having an ethylacrylate content of less than <NUM>%, available from Rohm and Haas (Dow Chemical) under the trade name Paraloid™ EXL-<NUM>. It will be recognized that combinations of impact modifiers may be used. In some aspects, the impact modifier may be present in an amount from greater than <NUM> wt. % to <NUM> wt. % or from greater than <NUM> wt. % to about <NUM> wt. In further aspects, the impact modifier is present in an amount from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt.

In a further aspect, the disclosed thermoplastic compositions can further include an antioxidant or "stabilizer. " Numerous stabilizers are known may be used, in one aspect the stabilizer is a hindered phenol, such as Irganox™ <NUM>, available from BASF. In some aspects, the stabilizer may be present in an amount from greater than <NUM> wt. % to <NUM> wt. % or from greater than <NUM> wt. % to about <NUM> wt. In further aspects, the stabilizer is present in an amount from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt.

In a further aspect, the disclosed thermoplastic compositions can further include a laser direct structuring additive. The laser direct structuring additive includes copper chromite black, copper hydroxide phosphate, tin-antimony cassiterite grey or a combination thereof. The laser direct structuring additive may be present in an amount from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt. % or from about <NUM> wt. % to about <NUM> wt. %, or from <NUM> wt. % to <NUM> wt.

The thermoplastic compositions of the present disclosure can be blended with the aforementioned ingredients by a variety of methods involving intimate admixing of the materials with any additional additives desired in the formulation. Because of the availability of melt blending equipment in commercial polymer processing facilities, melt processing methods are generally preferred. Illustrative examples of equipment used in such melt processing methods include: co-rotating and counter-rotating extruders, single screw extruders, co-kneaders, disc-pack processors and various other types of extrusion equipment. The temperature of the melt in the present process is preferably minimized in order to avoid excessive degradation of the resins. It is often desirable to maintain the melt temperature between <NUM> and <NUM> (or about <NUM> and about <NUM>) in the molten resin composition, although higher temperatures can be used provided that the residence time of the resin in the processing equipment is kept short. In some aspects the melt processed composition exits processing equipment such as an extruder through small exit holes in a die. The resulting strands of molten resin are cooled by passing the strands through a water bath. The cooled strands can be chopped into small pellets for packaging and further handling.

Compositions can be manufactured by various methods. For example, the polymeric base resin, and/or other optional components and additives are first blended in a HENSCHEL-Mixer™ high speed mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The blend is then fed into the throat of a twin-screw extruder via a hopper, while fiber filler, such as glass fiber, is fed into the extruder by a separate side feeder. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidefeeder. Additives can also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water batch and pelletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

The disclosed fiber-filled compositions provide improved mechanical properties when compared to compositions in the absence of the disclosed sized fiber filler. The disclosed sizing component at a fiber filler such as glass fiber may improve the interphase between the fiber filler and the polymer base resin matrix. The interphase may refer to the coupling or connection between the fiber filler and the polymer base resin. The sizing component comprising the sizing agent and reactive aid provide additional reactive elements that may link resin and fiber, thereby improving the interphase and ultimately improving overall strength of the composition.

As noted herein, the polymer base resin may comprise certain functional endgroups or moieties. These functional endgroups further promote interaction between the polymer base resin and the disclosed sized fiber filler. Exemplary functional endgroups may include hydroxyl, carboxyl, thiol, amine, or epoxy endgroups or a combination thereof.

A molded article formed from the disclosed composition may exhibit a notched Izod impact strength of <NUM> to <NUM> J/m when tested in accordance with ASTM D256. The molded article may exhibit an unnotched impact strength of <NUM> to <NUM> J/m when tested in accordance with ASTM D256.

Moreover, the disclosed sized fiber filler may provide improved flame retardance properties where a flame retardant additive is present. It is known in the art that the presence of a flame retardant in the composition may negatively affect impact strength to some degree. The disclosed compositions may exhibit a flame retardance of at least V0 at <NUM> when tested in accordance with UL <NUM> and may exhibit a notched Izod impact strength of <NUM> to <NUM> J/m when tested in accordance with ASTM D256.

Flammability tests were performed following the procedure of Underwriter's Laboratory Bulletin <NUM> entitled "Tests for Flammability of Plastic Materials, UL <NUM>". Several ratings can be applied based on the rate of burning, time to extinguish, ability to resist dripping, and whether or not drips are burning. Bar thicknesses were <NUM> or <NUM>. Materials can be classified according to this procedure as UL <NUM> HB (horizontal burn), V0, V1, V2, 5VA and/or 5VB on the basis of the test results obtained for five samples; however, the compositions herein were tested and classified only as V0, V1, and V2, the criteria for each of which are described below. These criteria are dependent upon flame out times (FOTs) and are sensitive to dripping of the molten sample. If the molten sample does not ignite underlying cotton wool (i.e., a non-burning drip, "NB"), it does not affect the flammability rating. Where the molten burning sample does ignite the underlying cotton wool, it is indicated as a burning drip (BD). Individual flame out times of five bars tested with a FOT of <NUM> seconds or fewer receive a UL94-V1 or UL94-V2 rating. Individual FOTs of fewer than <NUM> seconds obtain a UL94-V0 rating.

V0: In a sample placed so that its long axis is <NUM> degrees to the flame, the period of flaming and/or smoldering after removing the igniting flame does not exceed ten (<NUM>) seconds and the vertically placed sample produces no drips of burning particles that ignite absorbent cotton. Five bar flame out time is the flame out time for five bars, each lit twice, in which the sum of time to flame out for the first (t1) and second (t2) ignitions is less than or equal to a maximum flame out time (t1+t2) of <NUM> seconds.

V1: In a sample placed so that its long axis is <NUM> degrees to the flame, the period of flaming and/or smoldering after removing the igniting flame does not exceed thirty (<NUM>) seconds and the vertically placed sample produces no drips of burning particles that ignite absorbent cotton. Five bar flame out time is the flame out time for five bars, each lit twice, in which the sum of time to flame out for the first (t1) and second (t2) ignitions is less than or equal to a maximum flame out time (t1+t2) of <NUM> seconds.

V2: In a sample placed so that its long axis is <NUM> degrees to the flame, the average period of flaming and/or smoldering after removing the igniting flame does not exceed thirty (<NUM>) seconds, but the vertically placed samples produce drips of burning particles that ignite cotton. Five bar flame out time is the flame out time for five bars, each lit twice, in which the sum of time to flame out for the first (t1) and second (t2) ignitions is less than or equal to a maximum flame out time (t1+t2) of <NUM> seconds.

The disclosure pertains to shaped, formed, or molded articles comprising the sized-fiber filled compositions. The thermoplastic compositions can be molded into useful shaped articles by a variety of means such as injection molding, extrusion, rotational molding, blow molding and thermoforming to form articles and structural components of, for example, personal or commercial consumer electronics, including but not limited to cellular telephones, tablet computers, personal computers, notebook and portable computers, and other such equipment, medical applications, RFID applications, and automotive applications. In a further aspect, the article is extrusion molded. In a still further aspect, the article is injection molded.

In a further aspect, the resulting disclosed compositions can be used to provide any desired shaped, formed, or molded articles. For example, the disclosed compositions can be molded into useful shaped articles by a variety of means such as injection molding, extrusion, rotational molding, blow molding and thermoforming. As noted above, the disclosed compositions are particularly well suited for use in the manufacture of electronic components and devices. As such, according to some aspects, the disclosed thermoplastic compositions can be used to form articles such as components of consumer electronics devices.

Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the embodiments "consisting of" and "consisting essentially of. " Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

As used in the specification and the appended claims, the singular forms "a" "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a polymeric base resin" includes mixtures of two or more polymeric base resins.

As used herein, the term "combination" is inclusive of blends, mixtures, alloys, reaction products, and the like.

Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent 'about,' it will be understood that the particular value forms another aspect. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself.

As used herein, the terms "about" and "at or about" mean that the amount or value in question can be the designated value, approximately the designated value, or about the same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ±<NUM>% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is "about" or "approximate" whether or not expressly stated to be such. It is understood that where "about" is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

As used herein, the terms "optional" or "optionally" means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Disclosed are the components to be used to prepare the compositions of the disclosure as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited each is individually and collectively contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.

References in the specification and concluding claims to parts by weight of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a compound containing <NUM> parts by weight of component X and <NUM> parts by weight component Y, X and Y are present at a weight ratio of <NUM>:<NUM>, and are present in such ratio regardless of whether additional components are contained in the compound.

A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

As used herein the terms "weight percent," "wt %," and "wt. %," which can be used interchangeably, indicate the percent by weight of a given component based on the total weight of the composition, unless otherwise specified. That is, unless otherwise specified, all wt. % values are based on the total weight of the composition. It should be understood that the sum of wt. % values for all components in a disclosed composition or formulation are equal to <NUM>.

Certain abbreviations are defined as follows: "g" is grams, "kg" is kilograms, "°C" is degrees Celsius, "min" is minutes, "mm" is millimeter, "MPa" is megapascal.

Unless otherwise stated to the contrary herein, all test standards are the most recent standard in effect at the time of filing this application.

Each of the materials disclosed herein are either commercially available and/or the methods for the production thereof are known to those of skill in the art.

It is understood that the compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

In various aspects, the present disclosure pertains to compositions as herein described comprising a polymeric base resin, a fiber filler with the sizing component, and a flame retardant additive and/or a laser direct structuring additive.

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in °C or is at ambient temperature, and pressure is at or near atmospheric. Unless indicated otherwise, percentages referring to composition are in terms of wt.

The materials listed in Table <NUM> were used to prepare comparative and inventive samples.

Sizing of the glass fiber GF1, GF2, and GF3 are summarized in Table <NUM>.

Samples (C1 and C2) and samples (E1 - E3), which already have impact modifiers in their formulation, were prepared from the foregoing components. Samples C1, C2 and E2 are comparative samples. Samples E1 and E3 are inventive samples. Table <NUM> shows the comparative and inventive examples of <NUM>% and <NUM>% GF loaded formulation.

Samples C1, C2 and E2 are comparative reference examples. Samples E1 and E3 are inventive samples demonstrating the novelty of the disclosed compositions. Comparing E1 with C1, no significant impact improvement with the GF with additional reactive sizing in the <NUM> wt. % GF filled components. Comparing E2, E3 with C2, the <NUM> wt. % GF filled components with BPA-epoxy sizing agent with reactive aid IDPI (E2), did not show any performance improvement, whereas <NUM> wt. % GF filled components with BPA-epoxy sizing agent with reactive aids HDI and IDPI (E3) showed a significant notched impact improvement of about <NUM>%.

It is intuitive that more glass fiber in the formulation would have a higher negative effect on the impact performance. However, the examples demonstrate that the special sizing with HDI and IDPI (E3) as reactive aid helps in achieving a more desirable impact strength. This improvement was more prominent for the high GF loading formulations.

Sample (C3) and samples (E4 - E5) were prepared from the above components. Samples C3 and E4 are comparative samples. Sample E5 is an inventive sample. Table <NUM> presents the physical properties of each sample.

In Table <NUM>, the comparative examples of <NUM> wt. % GF filled composites are shown. The influence of special sizing on the impact property of the composite is more obvious. Comparing E4 and E5 to C3, the GF composites with GF sizing containing reactive agent as only IDPI (E4) does not help or even reduces the unnotched impact performance, while GF composites with GF sizing containing reactive agent as with HDI (E5) gives a significant impact improvement in both notched and unnotched impact of about <NUM>%. The other mechanical properties are very similar to C3.

Additionally both E4 and E5 showed benefit in flame retardant performance, i.e., the significantly reducing the burning time. These <NUM> samples had improved FR performance (flame out time) at <NUM>.

The interphase between glass fiber and polymer base resin was further studied using scanning electron micrography (SEM). <FIG> presents the SEM for comparative sample C3. <FIG> presents inventive sample E5. <FIG> presents comparative sample E4. The observed sample is the fractured sample after impact testing. For both C3 and E4, it can be observed that the bonding of resin with flat GF is not as good. This is evidenced by the apparent gap between GF and the polymer resin shown as the white areas that are not surrounded or coated by the sizing component having reactive aid. For E5, a better adhesion between the fiber and the resin was observed. The better adhesion is the bonding of glass fiber with the polymer resin and is evidenced by the apparent dark coating (sizing component) on the white areas (corresponding to the glass fiber). The improved bonding between resin and GF in E5 may correspond to improved impact performance due to efficient stress transfer from resin to fiber. In addition, the reactive aid reacts with the fiber and the resin thereby improving the dripping inhibition effect to improve the flame retardant performance.

Glass fibers (GF) were also used in compounds with Laser Direct Structuring (LDS) function. For the LDS compounds, LDS additives typically cause a reduction in impact performance; as a result impact modifiers are included. The examples, however, demonstrate that the GF3 with a special sizing of HDI and IDPI helps to achieve a more desirable impact performance for the impact modified LDS compounds. Comparative sample (C4) and inventive sample (E6) including a <NUM> wt. % GF loaded formulation were prepared from the components as shown in Table <NUM>:.

As shown in Table <NUM>, inventive sample (E6) including <NUM> wt. % GF3 and reactive aids HDI and IDPI had significantly improved impact strength (<NUM>% higher NII; <NUM>% higher UNII) as compared to the comparative sample (C4).

Claim 1:
A composition comprising:
a polymer base resin;
from <NUM> wt.% to <NUM> wt.% of a fiber filler comprising a sizing component comprising a sizing agent and a reactive aid comprising a diisocyanate compound which comprises hexamethylene diisocyanate, wherein the sizing component is present as a coating on the fiber filler, and wherein the sizing component is present in an amount of from <NUM> wt.% to <NUM> wt.% based on the weight of the fiber filler, and the reactive aid comprising the diisocyanate compound is present in an amount of from <NUM> wt.% to <NUM> wt.% based on the weight of the sizing component; and
an additive.