Granted Patent B2

US 12,371,566 · App. 17/609,015 · Granted Jul 29, 2025

Inventors: Pascal Lefevre (Lebbeke, BE); Glenn P. Desio (Marietta, GA)

Assignee: SOLVAY SPECIALTY POLYMERS USA, LLC

C08L77/06

Abstract

Claims (93)

1. A polyamide molding composition, comprising the following melt-blended components:

at least one polyamide (P1) consisting essentially of recurring units (R PA ) according to formula (I):

wherein n is 4, and

R 1 is a mixture of m-xylylene and p-xylylene in a mol. % ratio varying between 1:99 and 99:1,

at least one polymer (P2) such that:

Tm ( P 2)≥ Tm ( P 1),

with Tm(P2) and Tm(P1) being respectively the melting point of P2 and P1,

Tc ( P 2)> Tc ( P 1),

with Tc(P2) and Tc(P1) being respectively the crystallization temperature of P2 and P1 upon cooling from the melt, and

Tm ( P 2)− Tc ( P 2)< Tm ( P 1)− Tc ( P 1)

optionally at least one reinforcing agent,

optionally at least one component selected from the group consisting of tougheners, plasticizers, colorants, pigments, antistatic agents, dyes, lubricants, thermal stabilizers, light stabilizers, flame retardants, nucleating agents and antioxidants;

wherein

the weight ratio of P1/P2 varies between 15/1 and 1/1, inclusive and

polymer (P2) comprises recurring units (R PA2 ) according to formula (V):

wherein m varies between 6 and 18, inclusive and R 1 is p-xylylene.

2. The composition of claim 1 , comprising at least 50 mol. % of recurring units (R PA ) according to formula (I), based on the total number of moles in the polyamide (P1).

3. The composition of claim 1 , wherein the polyamide (P1) is the condensation product of a mixture comprising:

at least one diamine component which is blend of m-xylylene diamine and p-xylylene diamine, and

at least one dicarboxylic acid HOOC—(CH 2 ) n —COOH, wherein n is 4.

4. The composition of claim 1 , comprising from 10 wt. % to 60 wt. % of the at least one fiber reinforcement selected from the group consisting of glass fibers, carbon fibers, or mixtures thereof, based on the total weight of the composition.

5. The composition of claim 1 , comprising from 0.5 wt. % to 5 wt. % of pigment, dye or colorant selected from the group consisting of TiO 2 , carbon black, zinc sulfide, barium sulfate, zinc oxide, ferric oxide and any combination of one or more thereof, based on the total weight of the composition.

6. The composition of claim 1 , comprising from 20 wt. % to 70 wt. % of the polyamide (P1), based on the total weight of the composition.

7. The polyamide molding composition of claim 1 , wherein polymer (P2) is the condensation product of a mixture comprising at least one diamine component which is the p-xylylene diamine, and at least one diacid component which is a dicarboxylic acid HOOC—(CH 2 ) m —COOH wherein m varies between 6 and 18 inclusive or derivatives thereof.

8. The polyamide molding composition of claim 1 , wherein polymer (P2) is the condensation product of a mixture comprising at least one diamine component which is the p-xylylene diamine, and at least one diacid component which is sebacic acid.

9. A process to manufacture an article using molding, comprising the steps of: heating a melt-blended polyamide molding composition comprising:

at least one polyamide (P1) comprising recurring units (R PA ) according to formula (I):

n varies is 4; and

R 1 is a mixture of m-xylylene and p-xylylene;

at least one polymer (P2) comprising recurring units (R PA2 ) according to formula

m varies between 6 and 18, inclusive and R 1 is p-xylylene

Tm(P2)≥Tm(P1), with Tm(P2) and Tm(P1) being respectively the melting point of P2 and P1;

Tc(P2)≥Tc(P1), with Tc(P2) and Tc(P1) being respectively the crystallization temperature of P2 and P1 upon cooling from the melt;

Tm ( P 2)− Tc ( P 2)< Tm ( P 1)− Tc ( P 1); and

the weight ratio of P1/P2 varies between 15/1 and 1/1;

optionally at least one reinforcing agent,

optionally at least one component selected from the group consisting of tougheners, plasticizers, colorants, pigments, antistatic agents, dyes, lubricants, thermal stabilizers, light stabilizers, flame retardants, nucleating agents and antioxidants;

heating a mold to a temperature of less than 110° C.; injecting the melted composition into the heated mold; and releasing the molded article, wherein the molded article has a calculated percentage of crystallinity higher than 90%, as calculated according to the following equation:

%

⁢

⁢

of

⁢

⁢

crystallinity

=

Δ

⁢

H

⁢

f

-

Δ

⁢

H

⁢

c

Δ

⁢

H

⁢

f

×

1

⁢

0

⁢

0

wherein ΔHf is the enthalpy of fusion at 1 st heating (J/g), ΔHc is the crystallization enthalpy at 1 st heating (J/g), and both ΔHf and ΔHc are measured by DSC according to ASTM D3418.

10. The process of claim 9 , wherein water is used to heat the mold.

11. A molded article comprising a melt-blended polyamide molding composition, the polyamide molding composition comprising:

at least one polyamide (P1) comprising recurring units (R PA ) according to formula (I):

n is 4; and

R 1 is a mixture of m-xylylene and p-xylylene in a mol. % ratio varying between 1:99 and 99:1;

at least one polymer (P2) comprising recurring units (R PA2 ) according to formula (V):

where

m varies between 6 and 18, inclusive and R 1 is p-xylylene

Tm(P2)≥Tm(P1), with Tm(P2) and Tm(P1) being respectively the melting point of P2 and P1;

Tc(P2)>Tc(P1), with Tc(P2) and Tc(P1) being respectively the crystallization temperature of P2 and P1 upon cooling from the melt;

Tm ( P 2)− Tc ( P 2)< Tm ( P 1)− Tc ( P 1); and

the weight ratio of P1/P2 varies between 15/1 and 1/1;

optionally at least one reinforcing agent; and

optionally at least one component selected from the group consisting of tougheners, plasticizers, colorants, pigments, antistatic agents, dyes, lubricants, thermal stabilizers, light t stabilizers, flame retardants, nucleating agents and antioxidants;

wherein the molded article has a calculated percentage of crystallinity higher than 90%, as calculated according to the following equation:

% of crystallinity=Δ Hf−ΔHc/ΔHf× 100

wherein ΔHf is the enthalpy of fusion at 1st heating (J/g), ΔHc is the crystallization enthalpy at 1st heating (J/g), and both ΔHf and ΔHc are measured by DSC according to ASTM D3418.

12. The article of claim 11 , comprising at least one of the following properties:

an impact strength of at least 40 KJ/m 2 , as measured according to ISO 180/1U;

a modulus of at least 18 GPa, as measured according to ISO527;

a gloss of at least 1.5 at 20° as measured according to ISO2813, when molded at 90° C.;

a gloss of at least 3 at 20°, at least 15 at 60° and at least 20 at 85° as measured according to ISO2813, when molded at 100° C.;

a surface rugosity of less than 1.5 μm as measured according to ISO 4287:1997, when molded at 90° C.; or

a surface rugosity of less than 1 μm as measured according to ISO 4287:1997, when molded at 100° C.

Assignments (1)

Priority Claims (1)

Continuity (2)

References Cited (15)