Articles manufactured wholly or partly from a polymer mixture and comprising a lacquer layer or an adhesive layer.

0001General Electric Company, Schenectady, New York, U.S.A. Applicant mentions as inventor: Roelof van der Meer.

0002Article manufactured wholly or partly from a polymer mixture and comprising a lacquer layer or an adhesive layer.

0003The invention relates to an article from a polymer mixture which comprises a polyphenylene ether, optionally a polystyrene or a rubber-modified polystyrene, and is provided with a lacquer layer or an adhesive layer.

0004Articles manufactured from a polyphenylene ether and having a polyurethane lacquer layer are known from French Patent Application 2,293,892. The known articles are manufactured from a polyphenylene ether without any further additions. In such articles a good adhesion between the polyurethane lacquer or adhesive layer is of importance.

0005The invention provides articles having a good adhesion between the lacquer layer or adhesive layer and the actual article.

0006In particular, the invention provides articles having a lacquer layer on the bais of a polyurethane or an alkyd/melamine or having a polyurethane- or epoxy adhesive layer.

0007The article according to the invention is characterized in that it is manufactured from a polymer mixture comprising a polyphenylene ether and a epoxy compound.

0008Polymer mixtures comprising a polyphenylene ether, optionally a polystyrene or a rubber-modified polystyrene and an epoxy compound, are known per se from Japanese Patent Application 45/120514 laid open to public inspection under No. 48/39017.

0009Chemical Abstract, Vol. 81, no. 20, November 1974, number 122,066 u describes an adhesive composition containing poly(phenylene oxide) and an epoxy resin having good adhesion to copper foils. The composition is adhered to the copper foil at elevated temperature (300°C) and pressure (50 - 100 kg/cm³).

0010It is furthermore known from German Patent Application 30.39201 that the adhesion of polyurethane foam to articles formed from a polyphenylene ether- polystyrene mixture can be improved by the addition of a special impact-proof modified polystyrene as described in German Patent Application 25 25 019.

0011A good adhesion with lacquers and adhesives can be obtained when the article is manufactured from a polymer mixture which in addition comprises a block copolymer having blocks derived from a conjugated diene and from a vinyl aromatic compound. This applies in particular to the adhesion with lacquers, for example, polyurethane lacquers and alkyd/melamine lacquers.

0012The articles according to the invention are manufactured from a polymer mixture comprising the following constituents: <ul id="ul0001" list-style="none"><li>A. a polyphenylene ether;</li><li>B. an epoxy compound.</li></ul>

0013This polymer mixture may furthermore comprise: <ul id="ul0002" list-style="none"><li>C. a saturated or unsaturated block copolymer;</li><li>D. a polystyrene or a rubber-modified polystyrene;</li><li>E. usual additives for polymer mixtures comprising a polyphenylene ether.</li></ul>

A.Polyphenylene ether.

0014Polyphenylene ethers and their preparation are described in numerous patent publications, for example, in United States Patents 3,306,874; 3,306,875; 3,257,357 and 3,257,358. The polymer mixture according to the invention may comprise one or more of all the known polyphenylene ethers, notable also homopolymers, copolymers and graft copolymers. The polyphenylene ether in the polymer mixtures according to the invention preferably comprises units derived from 2,6-dimethylphenol.

B. Epoxy compound.

0015The following compounds may be used as an epoxy compound: <ul id="ul0003" list-style="none"><li>(1) Epoxide resins which are prepared by condensing phenols having two or more OH-groups with epichlorohydrin in various ratios.</li><li>(2) Epoxide resins which are prepared by condensing alcohols having two or more OH-groups (= poly alcohols) with epichlorohydrin.</li><li>(3) Glycidyl ethers derived from phenols or alcohols having one OH-group.</li><li>(4) Glycidyl ethers derived from amine compounds.</li><li>(5) Epoxidized higher olefins or cycloalkanes.</li></ul>

0016Typical examples of epoxide resins mentioned B (1) are the condensation products of bisphenol A or bisphenol F with epichlorohydrin (for example, Araldit GT 7071, Araldit GY 266 and Araldit GT 6099 of Ciba _Geigy), condensation products of resorcinol and epichlorohydrin, condensates of tetrabromobisphenol A and epichlorohydrin and the glycidyl ether products of phenol Novolak or kresol Novolak, for example Ciba _EPN 138 of Ciba Geigy. Condensates of phenols having two OH-groups and epichlorohydrin having a reasonably high molecular weight, for example the phenoxy resins produced by Union Carbide Corp., may also be used.

0017As examples of the epoxide resins mentioned B (2) may be stated the condensates of ethylene glycol, propylene glycol, butylene glycol, polyethylene glycol, glycerin, trimethylol ethane, trimethylol propane, or pentaerythritol with epichlorohydrin.

0018As examples of the glycidyl ether products B (3) may be mentioned phenyl glycidyl ether, n-butyl glycidyl ether, cresyl glycidyl ether, and 2_-ethylhexyl glycidyl ether.

0019As an example for B (4) is mentioned a diglycidyl ether derived from aniline.

0020As an example of the compounds mentioned B (5) may be stated epoxidized unsaturated oils, for example, soya bean oil and linseed oil (Edenol D 81 and Edenol B 316, respectively, of Henkel).

0021Due to the small plasticizing effect in polymer mixtures comprising a polyphenylene ether, epoxy resins having a molecular weight or more than 1,000 are preferably used.

C. Saturated or unsaturated block copolymer.

0022Block copolymers which may be used in the polymer mixtures: block copolymers of the type A-B, A-B-A' or also radial teleblock copolymers and so-called tapered block copolymers, i.e. block copolymers in which copolymers of the conjugated diene and the vinyl aromatic compound are present between the blocks. The block built up from the conjugated diene in all the types of block copolymers considered here may be fully or partly hydrogenated, in which case saturated block copolymers are obtained. In the block copolymers A-B and A-B-A', B consists of a block of a conjugated diene, for example, butadiene, isoprene or pentadiene-1,3, and blocks A and A' consist of vinyl aromates, for example, styrene, alpha-methylstyrene, vinyl toluene, vinyl xylene and/or vinyl naphtalene. B preferably consists of polybutadiene and A and A' preferably consist of polystyrene. Radial teleblock copolymers are to be understood to mean brancsal urbzjanf sigtex cbroyf which are formed by a polymer of a conjugated diene, preferably butadiene, blocks of a vinyl aromatic compound, preferably styrene and a coupling agent. In this copolymer structure, various chains of the diene polymer, usually three or more, start from a coupling agent in which each chain at its other end comprises a block of the aromatic vinylpolymer. All the said block copolymers are known per se.

0023D. Polystyrene or rubber-modified polystyrene.

0024As a polystyrene there may be used a compound which contains more than 25% of units of a compound of the formula R-C(C₆H(₅-p)Zp) = CH₂, wherein R is a hydrogen atom, a lower alkyl group (having, for example, 1-6 carbon atoms) or a halogen atom, Z is a hydrogen atom or a chlorine atom or a lower alkyl group or a vinyl group and p = O or an integer from 1 to 5.

0025Suitable polystyrene compounds and suitable rubber-modified polystyrene compounds (high-impact polystyrene) are homopolymers, for example, polystyrene itself, polychlorostyrene and poly-alpha-methyl styrene, rubber-modified polystyrenes, for example, the commercially available high-impact polystyrene polymers and also the styrene-containing copolymers, for example, styrene acrylonitrile copolymers, styrene butadiene copolymers, styrene acrylonitrile-butadiene terpolymers, copolymers of ethylvinylbenzene and divinylbenzene and the like.

0026When the polymer mixture includes a polystyrene or a rubber-modified polystyrene, the ratio between the quantity by weight of polyphenylene ether and polystyrene may be varied within wide limits, for example, between 1:4 and 20:1.

0027E. Usual additives for polymer mixtures of polyphenylene ether.

0028Examples of usual additives are dyes and pigments, agents to make the polymer mixture antistatic, agents to give the polymer mixture better flame- retarding properties, stabilizers, fillers, reinforcing fibres and mineral oil.

0029The articles according to the invention are manufactured according to usual techniques of processing synthetic resins, for example, by injection moulding, extrusion and the like. Layers of lacquer or adhesive on the basis of a polyurethane may be provided on the articles. Lacquers on the basis of an alkyd/ melamine system or epoxy adhesives may also be provided.

0030Polyurethane lacquers or adhesives are to be understood to mean lacquers or adhesives which comprise urethane groups in the ultimate protective layer or in the ultimately formed compound. Urethane groups are formed by the reaction of an active hydrogen atom of a hydroxyl group with an isocyanate group.

0031In most cases a polyurethane lacquer or adhesive consists of two components which are mixed with each other immediately before use. The two components are usually a prepolymer with isocyanate end groups and a resin with reactive OH-groups. In Verfkroniek, 43 (1970), p. 269-276 are mentioned as examples of suitable reactive resins: <ul id="ul0004" list-style="none"><li>a. polyacrylate-polyol</li><li>b. polyester-polyol</li><li>c. polyether-polyol</li></ul>

0032The OH-value of the lacquer or adhesive determines the ultimate degree of cross-linking of the lacquer or adhesive. The lacquer or adhesive usually comprises one or more of the following solvents: ethyl acetate, butyl acetate, toluene and xylene.

0033Alkyd/melamine lacquers are baking enamels. By raising the temperature (baking), curing takes place. The two components, on the one hand the alkyd resin with free carboxyl groups and on the other hand the melamine resin with free OH-groups, are supplied as one system.

0034Suitable epoxy adhesives are two-components systems which are mixed immediately before use. The main component is an epoxy resin having a given epoxy equivalent number, while the second component, "the hardener", ensures curing by reaction with the epoxy group.

0035In the examples hereinafter, thin, disk-shaped plates are formed by injection moulding from the polymer mixtures mentioned therein. Lacquer layers and/or adhesive layers on the basis of a polyurethane are provided on said plates. The bonding between the polyurethane lacquer layer - if not otherwise stated - is determined according to the so-called "GitterschnittprUfung von Anstrichen und ähnlichen Beschich- tungen" (cross-cut test on paint coatings and similar coatings) according to DIN 53 151. The tests have been carried out with an Ericsen type 295 testing apparatus. By means of said testing apparatus, a pattern of squares is scratched in the coating layer. An adhesive tape is adhered across said pattern; the tape is thoroughly pressed on. The adhesive tape is then pulled off. The appearance of the square pattern is then evaluated visually. With an evaluation Gto the coating layer is still fully intact. With an evaluation Gt5 more than 65% of the surface of the diamond pattern has worked loose. With intermediate evaluations Gtl, Gt2, Gt3, Gt4 a result getting worse and worse in this sequence is obtained.

0036The bonding of the adhesive layer is determined as follows. A standardized tensile test bar is manufactured from the polymer mixtures by injection moulding. A PVC-foil is adhered to the tensile test bar by means of adhesive (example III). The adhesive is cured. The peel resistance is then determined (N/mm). The peel resistance is defined as the average force per length unit of the bonding line to further pull apart the two parts bonded together once the peeling has started. For this method of determining the peel resistance there may be referred to International Standard ISO 4578-1979 (E) and to DIN 53 282. In example IV the bonding of the adhesive is determined by adhering two tensile test bars together with an overlap of 1 cm. The force necessary to slide the tensile test bars parallel to each other is then measured as the peel resistance (N/mm²).

Example I

0037Polymer mixtures were prepared (samples A, B and C) having a composition as stated in Table I hereinafter. From these mixtures, thin disc-shaped plates were manufactured by injection moulding. The plates were lacquered under different conditions with three commercially available polyurethane lacquers by means of a spray gun. The bonding between the plates and the lacquer layer was determined after seven days according to the "GitterschnittprUfung" (cross-cut test) (DIN 53151). The lacquer conditions and the results obtained are recorded in Tables II, III, IV, V and VI herein after. The tests were always carried out in quintuplicate. <tables id="tabl0001" num="0001"><img file="EP0137545A2_D0001.tif" /></tables><tables id="tabl0002" num="0002"><img file="EP0137545A2_D0002.tif" /></tables><tables id="tabl0003" num="0003"><img file="EP0137545A2_D0003.tif" /></tables><tables id="tabl0004" num="0004"><img file="EP0137545A2_D0004.tif" /></tables><tables id="tabl0005" num="0005"><img file="EP0137545A2_D0005.tif" /></tables><tables id="tabl0006" num="0006"><img file="EP0137545A2_D0006.tif" /></tables><tables id="tabl0007" num="0007"><img file="EP0137545A2_D0007.tif" /></tables><tables id="tabl0008" num="0008"><img file="EP0137545A2_D0008.tif" /></tables><ul id="ul0005" list-style="none"><li>3. Lacquer I is a two components polyacrylate-polyol/ isocyanate having an OH-value of 4%, commercially available as "Autocryl" from Messrs. Sikkens.</li><li>4. Lacquer II is a two components polyacrylate-polyol/ isocyanate lacquer having an OH-value of 4%, commercially available as "Cellioster 1834" from Messrs. La Celliose.</li></ul>

0038It appears from the Tables that the conditions upon spraying the lacquers are of importance for the resulting bonding. In practice, however, it is of essential importance that a good bonding should also be obtained in less optimum conditions.

0039It appears from the Tables that with the samples B and C according to the invention a better or equal result is obtained as with sample A (reference sample).

Example II.

0040Two polymer mixtures were prepared corresponding to samples A and B of Table I. Disk-shaped plates were manufactured from the polymer mixture by means of injection moulding. The plates were lacquered with a polyurethane lacquer under different conditions. As a polyurethane lacquer was used a two-components polyacrylatepolyol/isocyanate lacquer obtainable as "Cellioster 2400 Alu Nacre 3387 HU" from La Celliose.

0041All experiments were carried out in quintuplicate. The bonding strength was determined according to the "Gitterschnitt" test. Moreover the impact strength prior to and after painting was determined according to the so-called "falling dart impact" test (thickness disk 3.2 mm; falling height 2.15 m; mass 10.378 kg). The results are recorded in Table VII. <tables id="tabl0009" num="0009"><img file="EP0137545A2_D0009.tif" /></tables><tables id="tabl0010" num="0010"><img file="EP0137545A2_D0010.tif" /></tables>

0042It may be seen from Table VII that sample B according to the invention shows a better or equal bonding with polyurethane lacquer than sample A (reference sample).

Example III.

0043Three polymer mixtures were manufactured with the composition as stated hereinafter in Table VIII. <tables id="tabl0011" num="0011"><img file="EP0137545A2_D0011.tif" /></tables><tables id="tabl0012" num="0012"><img file="EP0137545A2_D0012.tif" /></tables>

0044Standardized rods for a tensile test were manufactured from the resulting polymer mixtures by injection moulding. A PVC foil was adhered to the rods by means of a polyurethane adhesive, namely a two-components polyurethane adhesive of the tradename "Hernerts 7550". The glued joint was heated at 80° C for 5 minutes. After 5 days the peel resistance was determined. The results are recorded in Table IX hereinafter. <tables id="tabl0013" num="0013"><img file="EP0137545A2_D0013.tif" /></tables>

Example IV.

0045A large number of tensile test bars were formed (injection moulded) from each of the polymer mixtures according to samples A, B and C of Example I. Always two rods from the same polymer mixture were bonded together with an overlap of 1 cm by means of a polyurethane adhesive or an epoxy adhesive. The adhesive was cured, partly at 20° C and partly at 80° C (60 minutes) and partly at 120° C (60 minutes). Two different polyurethane adhesives and one epoxy adhesive were used. Seven days after adhering the peel resistance was determined. Each test was repeated four times. The results obtained are recorded in Table X hereinafter. <tables id="tabl0014" num="0014"><img file="EP0137545A2_D0014.tif" /></tables>

0046It may be seen from the Table that the samples B and C according to the invention provide a better or equal peel resistance as compared with Sample A (not according to the invention).

Example V.

0047Polymer mixtures (samples G, H, J and K) were prepared in a composition as indicated in Table XI hereinafter. Injection moulding, lacquering and determination of bonding were carried out as stated in Example I. The results obtained are recorded in Table XII. <tables id="tabl0015" num="0015"><img file="EP0137545A2_D0015.tif" /></tables><tables id="tabl0016" num="0016"><img file="EP0137545A2_D0016.tif" /></tables>

0048It appears from Table XII that under critical lacquer conditions the sample with the block copolymer shows a better or equal bonding than the reference sample, while the sample with only the epoxide compound shows a better bonding, and the sample with both the block copolymer and the epoxide compound shows the best bonding.

Example VI.

0049Polymer mixtures were prepared having a composition as of sample A to which, however, 2.5 parts by weight of various epoxy compounds are added (Table XIII). The samples L, M, N and P were obtained in this manner (Table XIII). Injection moulding, lacquering and bonding determination were carried out as stated in Example I. The bonding found is recorded in Table XIV. <tables id="tabl0017" num="0017"><img file="EP0137545A2_D0017.tif" /></tables><tables id="tabl0018" num="0018"><img file="EP0137545A2_D0018.tif" /></tables><tables id="tabl0019" num="0019"><img file="EP0137545A2_D0019.tif" /></tables>

Example VII.

0050Test plates were manufactured from polymer mixtures according to samples A and C of Example I. The samples were lacquered by spraying with two different alkyd/melamine lacquers. The conditions during lacquering and the found bonding results are recorded in Table XV hereinafter. <tables id="tabl0020" num="0020"><img file="EP0137545A2_D0020.tif" /></tables><tables id="tabl0021" num="0021"><img file="EP0137545A2_D0021.tif" /></tables>

0051It may be seen from the results recorded in Table XV that a better or equal bonding is obtained with a polymer mixture according to the invention B than with polymer mixture A (reference sample).