CAPROLACTAM FORMULATIONS

Abstract

A process for the production of a masterbatch (M) which includes at least one lactam and at least one fiber material is provided herein. Also described herein is the masterbatch (M) and a polymerizable two-component system (pS), as well as a process for the production of a polyamide (P), the use of the masterbatch (M) for the production of the polyamide (P), and the polyamide (P). A molding made of the polyamide (P) is also described.

Claims

1. A process for the production of a masterbatch (M) that includes the following components: (A) at least one lactam, and (D) at least one fiber material, wherein the process comprises compounding the components (A) and (D) in an extruder with a shear rate of at least 500 s.sup.1, wherein the extruder includes at least the following sections: (I) a first section, (II) a second section, and (III) a third section, wherein the first section (I) has a first temperature (T1), the second section (II) has a second temperature (T2), and the third section (III) has a third temperature (T3), and wherein the second temperature (T2) is in a range from 105 C. to 220 C.

2. (canceled)

3. The process according to claim 1, wherein the first temperature (T1) is in a range from 20 C. to 70 C.

4. The process according to claim 1, wherein the second section (II) of the extruder includes from 2 to 10 kneading zones and from 1 to 10 conveying zones.

5. The process according to claim 1, wherein the masterbatch (M) comprises from 1 to 90% by weight of the component (D), based on a total weight of the masterbatch (M).

6. The process according to claim 1, wherein the component (D) is selected from the group consisting of glassfiber materials, carbon fiber materials, aramid fiber materials, poly(p-phenylene-2,6-benzobisoxazole) fiber materials, boron fiber materials, metal fiber materials, and potassium titanate fiber materials.

7. The process according to claim 1, wherein the component (D) is in a form of an individual fiber of length in a range from 10 m to 1000 m.

8. The process according to claim 1, wherein the masterbatch (M) also comprises a component (E) including at least one thickener, wherein the component (E) is selected from the group consisting of thermoplastic polystyrenes, polysulfones, polyphenyl ethers, polybutadienes, polyisoprenes, and nanofillers.

9. The process according to claim 1, further comprising: a) introducing the component (A) into the extruder, b) adding the component (D) in a form selected from the group consisting of rovings, chopped glass fibers, ground glass fibers, and prepregs to the component (A) in the extruder, and c) said compounding the components (A) and (D) in the extruder to produce the masterbatch (M).

10. A masterbatch (M) obtainable by a process according to claim 1.

11. A polymerizable two-component system (pS) that comprises, separately from one another: i) a first system component (sK1) that comprises a masterbatch (M) in accordance with claim 10 and one of: (B) at least one catalyst, and (C) at least one activator, and ii) a second system component (sK2) that comprises the following components: (A) at least one lactam, and the other of: (B) at least one catalyst, and (C) at least one activator, such that the polymerizable two-component system (pS) comprises the components (B) and (C).

12. A process for the production of a polyamide (P), the process comprising the following steps: a) providing a polymerizable two-component system (pS) according to claim 11, b) mixing the first system component (sK1) and the second system component (sK2) to give a polymerizable mixture (pM), c) polymerizing the polymerizable mixture (pM) to produce the polyamide (P).

13. A process for the production of a polyamide (P), the process comprising using the masterbatch (M) according to claim 10 to produce a polyamide (P).

14. A polyamide (P) obtainable by a process according to claim 12.

15. A molding made of the polyamide (P) according to claim 14.

16. The process according to claim 1, wherein the third temperature (T3) is in a range from 20 C. to less than 105 C.

17. The process according to claim 1, wherein the third section (III) of the extruder comprises from 1 to 5 mixing zones, from 1 to 5 kneading zones, from 2 to 10 conveying zones, and from 1 to 5 flow-restricting zones.

Description

COMPARATIVE EXAMPLE 1

[0325] An extruder with three sections was used. The first section (I) comprised a zone with prevailing temperature 35 C., the second section (II) comprised 4 zones with the following temperatures: 170 C., 170 C., 130 C., and 90 C. The third section (III) comprised 8 zones with the following temperatures: 70 C., 60 C., 50 C., 50 C., 40 C., 40 C., 40 C., and 40 C. The respective temperatures are based on the jacket temperatures of the extruder.

[0326] 200 g of thickener (Styroflex, 2G66 from Styrolution) were mixed with 5000 g of caprolactam. This mixture was introduced into the first zone of the first section (I) (35 C.) of the extruder. In the second zone (first zone of the second section (II)), 1 kg of glass fiber was metered into the system at 1.5 kg/h. In the sixth zone (first zone of the third section (III), 70 C.), 1.5 kg of caprolactam per hour were added. The extrusion product obtained was inhomogeneous and comprised clumps.

INVENTIVE EXAMPLE 2

[0327] An extruder with three sections was used. The first section (I) comprised a zone with prevailing temperature 35 C., the second section (II) comprised 4 zones with the following temperatures: 170 C., 170 C., 150 C., and 120 C. The third section (III) comprised 8 zones with the following temperatures: 100 C., 80 C., 60 C., 50 C., 40 C., 40 C., 40 C., and 40 C. The respective temperatures are based on the jacket temperatures of the extruder.

[0328] 200 g of thickener (Styroflex, 2G66 from Styrolution) were mixed with 5000 g of caprolactam. This mixture was introduced into the first zone of the first section (I) (35 C.) of the extruder. In the second zone (first zone of the second section (II), 170 C.), 1 kg of glass fiber was metered into the system at 1.5 kg/h. In the sixth zone (first zone of the third section (III), 70 C.), 1.5 kg of caprolactam per hour were added. The extrusion product obtained was homogeneous and comprised no clumps.

[0329] It can be seen that the quality of the product depends on the jacket temperature of the extruder, and that the jacket temperature in particular influences the homogeneity of the product.