IMPACT-RESISTANT COMPOSITIONS

COMPOSITIONS RESILIENTES

English Abstract

The invention relates to compositions comprising at
least one compound A, at least one linear or brancehed
polyester B, and at least one toughening agent C, the
linear or branched polyester B being produced from a
macrocyclic poly(.alpha.,.omega.-alkylene-terephthalate) or a
macrocyclic
poly(.alpha.,.omega.-alkylene-2,6-naphthalene
dicarboxylate) in the presence of an organotin catalyst
or organotitanium catalyst). Also
disclosed are a
method for producing said compounds and the use thereof
for producing composite members.

French Abstract

L'invention concerne des compositions contenant au moins un composé (A), au moins un polyester linéaire ou ramifié (B) et au moins un améliorateur de résistance (C). Le polyester linéaire ou ramifié (B) est fabriqué à partir d'un poly(a,?- alkylène-téréphtalate) macrocyclique ou d'un poly(a,?-alkylène-2,6-naphtaline-dicarboxylate) macrocyclique en présence d'un catalyseur organo-étain ou organo-titane. L'invention concerne également le procédé de fabrication desdites compositions et leur utilisation dans la fabrication de corps composites.

Claims

- 25 -
Claims
1. A composition comprising
at least one compound A which has at least two
glycidyl ether groups;
and also comprising a linear or branched polyester
B which is prepared from a macrocyclic poly(.alpha.,.omega.-
alkylene terephthalate) or from a macrocyclic
poly(.alpha.,.omega.-alkylene 2,6-naphthalenedicarboxylate) in
the presence of an organotin catalyst or of an
organotitanium catalyst;
and also comprising at least one toughness
improver C selected from the group consisting of a
block copolymer C3 which is composed of methyl
methacrylate, styrene, and butadiene, a reactive
liquid rubber C2, and a combination of a reactive
liquid rubber C2 and an ion exchanged lamellar
mineral C1;
wherein the reactive liquid rubber C2 has the
formula (X):
<IMG>

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Y1 is a q-valent radical of a polyurethane
linear or branched prepolymer terminated by
isocyanate groups, after removal of the
terminal isocyanate groups;
Y2 is a radical of an aliphatic, cycloaliphatic,
aromatic, or araliphatic epoxide comprising a
primary or secondary hydroxy group, after
removal of the hydroxide groups and epoxide
groups;
q = 2, 3, or 4; and
r = 1, 2, or 3.
2. The composition as claimed in claim 1, wherein the
compound A which has at least two glycidyl ether
groups is a diglycidyl ether of a bisphenol A or
of a bisphenol F, or of a bisphenol A/bisphenol F
mixture, or is a liquid oligomer thereof.
3. The composition as claimed in claim 1 or 2,
wherein the linear or branched polyester B is a
linear polyester B.
4. The composition as claimed in claim 3, wherein the
polyester B has the structural formula (II)

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<IMG>
where n = 1, 2, 3, or 4;
and where m = from 50 to 2000.
5. The composition according to claim 4, wherein n =
1 or 3.
6. The composition according to claim 4, wherein n =
3.
7. The composition according to any one of claims 4
to 6, wherein m = from 50 to 800.
8. The composition according to any one of claims 4
to 6, wherein m = from 50 to 600.
9. The composition according to any one of claims 4
to 6, wherein m = from 100 to 600.
10. The composition as claimed in claim 3, wherein the
polyester B has the structural formula (III)

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<IMG>
where n' = 1, 2, 3, or 4;
and where m' - from 50 to 2000.
11. The composition according to claim 10, wherein n'
= 1 or 3.
12. The composition according to claim 10, wherein n'
= 3.
13. The composition according to any one of claims 10
to 12, wherein m' - 50 to 800.
14. The composition according to any one of claims 10
to 12, wherein m' - 50 to 600.
15. The composition according to any one of claims 10
to 12, wherein m' - 100 to 600.
16. The composition as claimed in any one of claims 1
to 5, wherein the macrocyclic poly(.alpha.,.omega.-alkylene
terephthalate) or the macrocyclic poly(.alpha.,.omega.-
alkylene 2,6-naphthalenedicarboxylate) has the
structure of the formula (IV)

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<IMG>
where R = ethylene, propylene, butylene, or
pentylene;
and R' = <IMG> or <IMG>
where the broken lines indicate the bonds to R;
and where p has been selected so that the molar
mass M n of the macrocyclic poly(.alpha.,.omega.-alkylene
terephthalate) or of the macrocyclic poly(.alpha.,.omega.-
alkylene 2,6-naphthalenedicarboxylate) is from 300
to 2000 g/mol.
17. The composition according to claim 16, wherein R =
ethylene or butylene.
18. The composition according to claim 16, wherein R =
butylene.
19. The composition according to any one of claims 16
to 18, wherein the molar mass M n of the macrocyclic
poly(.alpha.,.omega.-alkylene terephthalate) or of the
macrocyclic poly(.alpha.,.omega.-alkylene 2,6
naphthalenedicarboxylate) is from 350 to 800
g/mol.

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20. The composition as claimed in any one of claims 1
to 19, wherein the ion-exchanged lamellar mineral
C1 is a cation-exchanged lamellar mineral C1c
which is obtained from a lamellar mineral C1' in
which at least a portion of the cations has been
exchanged for organic cations.
21. The composition as claimed in claim 20, wherein
the lamellar mineral C1' is a phyllosilicate.
22. The composition as claimed in claim 21, wherein
the lamellar mineral C1' is a kaolinite, a
montmorillonite, a hectorite, or an illite.
23. The composition as claimed in any one of claims 1
to 19, wherein the ion-exchanged lamellar mineral
C1 is an anion-exchanged lamellar mineral C1a
which is obtained from a lamellar mineral C1" in
which at least a portion of the anions has been
exchanged for organic anions.
24. The composition as claimed in claim 23, wherein
the lamellar mineral C1" is a hydrotalcite.
25. The composition as claimed in any one of claims 20
to 22, wherein the organic cations have the
formulae (V), (VI), (VII), (VIII), or (IX)
<IMG>

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<IMG>
R1 , R1' , R1", and R1'", independently of each other =
H, C1-C20-alkyl, substituted or unsubstituted aryl;
R2 = H, C1-C20-alkyl, substituted or unsubstituted
aryl;
R3 = H, C1-C20-alkyl, substituted or unsubstituted
aryl, or
R4 = H, C1-C20-alkyl, substituted or unsubstituted
aryl, or N(R2)2;
R5 = substituent which, together with the N+ shown
in formula (VII), forms an unsubstituted or
substituted ring of from 4 to 9 atoms, and which,
if appropriate, has double bonds;
R6 = substituent which, together with the N+ shown
in formula (VIII), forms an unsubstituted or
substituted bicyclic ring of from 6 to 12 atoms,

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and which, if appropriate, comprises further
heteroatoms or comprises cations of heteroatoms;
R7 = substituent which, together with the N+ shown
in formula (IX), forms an unsubstituted or
substituted heteroaromatic ring whose size is from
to 7 atoms.
26. The composition as claimed in any one of claims 1
to 25, wherein the amount of toughness improver C
is from 10 to 85% by weight, based on the total
weight of A + C.
27. The composition as claimed in any one of claims 1
to 26, wherein the amount of linear or branched
polyester B is from 85 to 98% by weight of the
composition.
28. A process for preparation of a composition as
claimed in any one of claims 1 to 27,
characterized in that it comprises the following
steps:
- formation of a premix AC of toughness improver
C and of the compound A which has at least two
glycidyl ether groups, and
- addition of the mixed premix AC to the
macrocyclic poly(.alpha.,.omega.-alkylene terephthalate) or
macrocyclic poly(.alpha.,.omega.-alkylene 2,6-
naphthalenedicarboxylate) which has been mixed
with the organotin catalyst or organotitanium
catalyst.

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29. The process as claimed in claim 28, wherein
preparation of the linear or branched polyester B
takes place at a temperature of from 160°C to
220°C, in the presence of the premix AC.
30. The process as claimed in claim 28, wherein
preparation of the linear or branched polyester B
takes place at a temperature of from 160°C to
200°C, in the presence of the premix AC.
31. The use of a premix AC of toughness improver C and
of the compound A which has at least two glycidyl
ether groups in preparation of the linear or
branched polyester B as defined in any one of
claims 1 to 27.
32. A composite product comprising a composition as
claimed in any one of claims 1 to 27 and also
comprising fibers, where the fibers are selected
from the group consisting of glass fibers, metal
fibers, carbon fibers, aramid fibers, mineral
fibers, plant fibers, and mixtures thereof.
33. The composite product as claimed in claim 32,
wherein the fibers are carbon fibers or metal
fibers.
34. The composite product as claimed in claim 32,
wherein the fibers are steel fibers.
35. The composite product as claimed in claim 32 or
34, wherein the proportion of fibers is from 30 to

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65% by volume, based on the volume of the
composite product.
36. The composite product as claimed in any one of
claims 32 to 35, wherein the shape of the
composite product is sheet-like.
37. A process for production of a composite product as
claimed in any one of claims 32 to 36, wherein the
composition in molten form is brought into contact
with the fibers and is solidified via cooling in a
mold.
38. The process as claimed in claim 37, wherein the
mold has an outlet through which the composite
product is continuously discharged during cooling.
39. The use of a composite product as claimed in any
one of claims 32 to 36, or of a composite product
produced by a process as claimed in claim 37 or
38, for the structural reinforcement of
construction work or of a conveyance.

Description

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IMPACT-RESISTANT COMPOSITIONS
Technical field
The invention relates to the field of impact-resistant
polyester compositions, in particular for use in fiber-
reinforced composite products.
Prior art
Thermoplastic polyesters are known plastics, and are
widely used. Desirable properties for their use in
fiber composites are not only good wetting of the
fibers, i.e. low viscosity during production of a
molding, but also high molecular weight, because of the
mechanical properties required. However, the viscosity
of the usual polyesters is too high for this
application, particularly when the polyesters are used
to produce moldings. US 5,498,651 discloses a
polymerization process starting from low-viscosity
macrocyclic polyester oligomers in the presence of
polymerization catalysts and of epoxides and/or of
thioepoxides. A particularly preferred epoxide
disclosed for this application is 3,4-epoxycyclohexyl
3,4-epoxycyclohexanecarboxylate. US 6,197,849 describes
organophilic phyllosilicates which are used as additive
in thermosets (thermoset polymers), in particular in
epoxy resins or in polyurethanes. US 5,707,439
describes the production of cation-exchanged lamellar
minerals. Polymerization of macrocyclic oligomers in
these cation-exchanged lamellar minerals is moreover
revealed. However, polymer mixtures of this type are
extremely difficult to process and lead to poor
mechanical properties, since the lamellar minerals can
act as nucleating agents.
Brief description of the invention
It is therefore an object of the present invention to
provide a composition which firstly has good
processability and secondly has increased impact

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resistance.
The composition as claimed in claim 1 achieves this
object.
Methods for carrying out the invention
The present invention relates to compositions which
encompass at least one compound A and also encompass at
least one linear or branched polyester B, and also
encompass at least one toughness improver C.
The compound A has at least two glycidyl ether groups
and is preferably a diglycidyl ether of a bisphenol A
or of a bisphenol F, or of a bisphenol A/bisphenol F
mixture, or is a liquid oligomer thereof. Diglycidyl
ethers of bisphenol A (DGEBA), of bisphenol F, and also
of bisphenol A/F have proven to be particularly
suitable compounds A (where the 'A/F' indicator here
refers to a mixture which is composed of bisphenol A
and of bisphenol F and which is used as starting
material in its preparation). By virtue of the
preparation processes for these resins it is clear that
there are also relatively high-molecular-weight
constituents in the liquid resins. The structure of
these diglycidyl ethers is shown by formula (I). The
degree of polymerization s in formula (I) for liquid
resins is typically from 0.05 to 0.20. These liquid
resins are available commercially, examples of typical
commercial products being Araldite GY 250, Araldite
PY 304, Araldite GY 282 (Huntsman), or D.E.R 331
(Dow).
R R' le le
____________________________________________________________________ n el = 00
I le ( I)
0 s
OH 0/

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Ra here is H or methyl.
Another possibility is that the compound A is a
relatively high-molecular-weight solid epoxy resin of
the formula (I) whose degree of polymerization s is
typically from 2 to 12. There is, of course, always a
distribution of molecular weights. Solid epoxy resins
of this type are available commercially, for example
from Dow or Huntsman or Resolution.
In one embodiment of the invention, a mixture of liquid
epoxy resin and solid epoxy resin is used. The ratio by
weight of liquid resin to solid resin is preferably
from 9 : 1 to 1 : 1.
In particular, the polyester B is a linear polyester
preferably having a structural formula (II) or (III).
0
11111
00
_ m
0
0
OS 0 C *
(M)
_ml
0
Each of the indices n and n' here means 1, 2, 3, or 4.
In particular, n = 1 or 3, and n' = 1 or 3. It is
preferable that n = 3 and n' = 3.
The indices m and m' have values from 50 to 2000, in
particular from 50 to 800, preferably from 50 to 600,
particularly preferably from 100 to 600.
Preferred polyesters B are poly(1,2-ethylene
terephthalate) (PET), poly(1,2-ethylene 2,6-naphthale-

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nedicarboxylate) (PEN), and
poly(1,4-butylene
terephthalate) (PBT). The most preferred polyester B is
poly(1,4-butylene terephthalate) (PBT).
The macrocyclic poly(a,w-alkylene terephthalate) or
macrocyclic poly(a,w-alkylene 2,6-
naphthalenedi-
carboxylate) used for preparation of the polyester B
preferably has the structure of the formula (IV)
_____________________________________ R'
(IV)
R here are an ethylene group, propylene group, butylene
group, or pentylene group, and R' is a group of the
formula
and R' = or
,0 SO
,0
0 0
The broken lines shown here are intended to indicate
the bonds to the alkylene group R, and the index p has
been selected so that the molar mass Mn of the
macrocyclic poly(a,w-alkylene terephthalate) or of the
macrocyclic poly(a,w-alkylene 2,6-naphthalenedi-
carboxylate) is from 300 to 2000 g/mol, in particular
from 350 to 800 g/mol.
A known method, for example as described in the patent
US 5,039,783, is used for preparation of the
macrocyclic poly(a,w-alkylene terephthalate) or of the
macrocyclic poly(a,w-alkylene 2,6-
naphthalenedi-
carboxylate).
The organotin catalyst or organotitanium catalyst
present in the preparation of the linear or branched

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polyester B is any catalyst known for this application
to the person skilled in the art - for example known
from US 5,407,984.
The amount of linear or branched polyester B in the
composition is preferably from 85 to 98% by weight,
with preference from 90 to 98% by weight, of the
composition.
The composition moreover encompasses at least one
toughness improver C. A "toughness improver" here and
hereinafter is a material which is added to a matrix
and which in particular in the case of thermosets, such
as epoxy resins, brings about a marked increase in
toughness when the amounts added are even as small as
from 0.5 to 8% by weight, and which is therefore
capable of absorbing a relatively high level of stress
due to bending, tension, or impact before any cracking
or breaking of the matrix occurs.
The toughness improver C is in particular an organic-
ion-exchanged lamellar mineral C1 or a reactive liquid
rubber C2, or a block copolymer C3.
The ion-exchanged lamellar mineral C1 can be either a
cation-exchanged lamellar mineral Clc or an anion-
exchanged lamellar mineral Cla.
The cation-exchanged lamellar mineral Clc is obtained
here from a lamellar mineral Cl' in which at least a
portion of the cations has been exchanged for organic
cations. Examples of these cation-exchanged lamellar
minerals Clc are in particular those mentioned in US
5,707,439 or in US 6,197,849. That literature also
describes the process for preparation of these cation-
exchanged lamellar minerals Clc. A phyllosilicate is
preferred as lamellar mineral C1'. The lamellar mineral
C1' is particularly preferably a phyllosilicate as
described in US 6,197,849 column 2, line 38 to column
3, line 5, in particular a bentonite. Lamellar minerals
C1' such as kaolinite or a montmorillonite or a

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hectorite or an illite have proven particularly
suitable.
At least a portion of the cations of the lamellar
mineral C1' is exchanged for organic cations. These
organic cations are in particular organic cations which
have the formulae (V), (VI), (VII), (VIII), or (IX).
Each of the substituents RP,
RI", and RP" is,
independently of the others, H or C1-C20-alkyl, or
substituted or unsubstituted aryl. It is preferable
that RI, RP, RI", and RP" are not the same substituent.
The substituent R2 is H or C1-C20-alkyl, or substituted
or unsubstituted aryl.
Rv
I +
R¨N¨R
I v.,
R3 /R2
(VI)
R4 \Ri
rTh R2
R5 N (VII)
\R1
R6i + 1
N¨R (VIII)
r"
R7
N¨R (IX)
Each of the substituents R3 and R4 is H or Ci-C20-alkyl,
or substituted or unsubstituted aryl, or an -N(R2)2
substituent. The substituent R5 is a substituent which,
together with the 1\1+ shown in formula (VII), forms an
unsubstituted or substituted ring of from 4 to 9 atoms,

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and which, if appropriate, has double bonds. The
substituent R6 is a substituent which, together with
the N+ shown in formula (VIII), forms an unsubstituted
or substituted bicyclic ring of from 6 to 12 atoms, and
which, if appropriate, comprises heteroatoms, such as
N, 0, and S, or their cations. The substituent R7 is a
substituent which, together with the N+ shown in
formula (IX), forms an unsubstituted or substituted
heteroaromatic ring whose size is from 5 to 7 atoms.
Specific examples of these organic cations of the
formula (V) are n-octylammonium (R1 n-octyl, = R1
- H), trimethyldodecylammonium (R1 = C12-alkyl,
- =
CH3), dimethyldodecylammonium (R1 = C12-
alkyl, CH3, R1" H) , or
bis(hydroxyethyl)octadecylammonium (R1 = C18-alkyl, R1' =
= CH2CH2OH, = H),
or similar derivatives of
amines which can be obtained from natural fats and
oils.
Specific examples of these organic cations of the
formula (VI) are guanidinium cations or amidinium
cations.
Specific examples of these organic cations of the
formula (VII) are N-substituted derivatives of
pyrrolidine, piperidine,
piperazine, morpholine,
thiomorpholine.
Specific examples of these organic cations of the
formula (VIII) are cations of 1,4-
diazobicyclo[2.2.2]octane (DABCO) and 1-
azobicyclo[2.2.2]octane.
Specific examples of these organic cations of the
formula (IX) are N-substituted derivatives of pyridine,
pyrrole, imidazole, oxazole, pyrimidine, quinoline,
isoquinoline, pyrazine, indole,
benzimidazole,
benzoxazole, thiazole, phenazine and 2,2'-bipyridine.
Further suitable cations are cyclic amidinium cations,
in particular those disclosed in US 6,197,849 in column
3, line 6 to column 4, line 67.
Cyclic ammonium compounds feature increased thermal

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stability when compared with linear ammonium compounds,
since they cannot undergo thermal Hoffmann degradation.
Preferred cation-exchanged lamellar minerals Clc are
known to the person skilled in the art by the term
organoclay or nanoclay, and are available commercially,
for example with the product group names Tixoge10, or
Nanofil (Stidchemie), Cloisite (Southern Clay
Products), or Nanomer0 (Nanocor Inc.).
The anion-exchanged lamellar mineral Cla is obtained
here from a lamellar mineral C1" in which at least a
portion of the anions has been exchanged for organic
anions. An example of an anion-exchanged lamellar
mineral Cla of this type is a hydrotalcite in which at
least a portion of the carbonate anions of the
intermediate layers has been exchanged for organic
anions.
It is certainly also possible that the composition
simultaneously comprises a cation-exchanged lamellar
mineral Clc and an anion-exchanged lamellar
mineral Cla.
The reactive liquid rubber C2 has functional groups
which at an elevated temperature, typically at a
temperature of from 80 C to 200 C, in particular from
100 C to 160 C, can react with themselves or with other
compounds in the composition. Particularly preferred
functional groups of this type are epoxide groups.
Particular preference is given to the reactive liquid
rubbers proposed for improving the toughness of epoxy
resin adhesives. The reactive liquid rubber C2 is
preferably a polyurethane prepolymer terminated by
glycidyl ether groups. Reactive liquid rubbers C2 of
the formula (X) have proven particularly suitable.

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_
r-
H 0 -
YNy0,,, -- (X)Q
Y2-] r
1
In formula (X), Y1 is a q-valent radical of a linear or
branched polyurethane prepolymer terminated by
isocyanate groups, after removal of the terminal
isocyanate groups, and Y2 is a radical of an aliphatic,
cycloaliphatic, aromatic, or araliphatic epoxide
comprising a primary or secondary hydroxy group, after
removal of the hydroxide groups and epoxide groups. The
index q here has a value of 2, 3, or 4, and the index r
has a value of 1, 2, or 3. In one embodiment, the
formula (X) has at least one aromatic structural
element which has bonding by way of urethane groups to
the polymer chain.
Liquid rubbers of the formula (XI) have proven to be
particularly advantageous.
-
H H _
(XI)
_w y
3 -
0 0
In formula (XI), Y3 is a (u+w)-valent radical of a
linear or branched polyurethane prepolymer terminated
by isocyanate groups, after removal of the terminal
isocyanate groups, and Y2 is a radical of an aliphatic,
cycloaliphatic, aromatic, or araliphatic epoxide
comprising a primary or secondary hydroxy group, after
removal of the hydroxide groups and epoxide groups. The
index w here has a value of 1, 2, or 3 and the index u
has a value of 4 - w, and the index v has a value of 1,
2, or 3. In formula (XI), X is either 0 or NH or N-
alkyl having from 1 to 6 carbon atoms, and R" is

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branched or unbranched alkyl or alkenyl substituents
having from 6 to 24 carbon atoms, or a
poly(dimethylsiloxane) radical whose molar mass is from
1000 to 10 000 g/mol. In one embodiment, the formula
(XI) has at least one aromatic structural element which
has bonding by way of urethane groups to the polymer
chain.
The preparation of these reactive liquid rubbers takes
place in the manner described by way of example in EP
1 431 325 Al, on page 4, line 37 to page 6, line 55.
Liquid rubbers C2 of the formulae (X) and (XI) can be
used individually or preferably in a mixture. If they
are used in a mixture, the ratio by weight of the
liquid rubbers of the formulae (X) and (XI), (X)/(XI),
is advantageously from 100:1 to 1:1.
The block copolymer C3 is obtained from anionic or
controlled free-radical polymerization of methacrylic
ester with at least one further monomer having an
olefinic double bond. A monomer having an olefinic
double bond is in particular one in which the double
bond has direct conjugation with a heteroatom or with
at least one further double bond. In particular,
suitable monomers are those selected from the group
consisting of styrene, butadiene, acrylonitrile, and
vinyl acetate.
Particularly preferred block copolymers C3 are block
copolymers composed of methyl methacrylate, styrene,
and butadiene. These block copolymers are available,
for example, in the form of triblock copolymers with
the product group name SBM from Arkema.
In one embodiment, the toughness improver C present in
the composition also comprises either a reactive liquid
rubber C2 or a block copolymer C3 alongside an ion-
exchanged lamellar mineral Cl. Particular preference is
given to the simultaneous presence of ion-exchanged

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lamellar mineral Cl and of reactive liquid rubber C2. A
cation-exchanged lamellar mineral Clc is preferred here
as ion-exchanged lamellar mineral C1.
The amount of toughness improver C is preferably from
to 85% by weight, based on the total weight of A +
C.
The composition can, if appropriate, have further
10 constituents, in particular fillers, plasticizers,
agents with thixotropic effect, adhesion-promoter
substances, in particular alkoxysilanes and titanates,
stabilizers, in particular heat stabilizers, such as
those known to the person skilled in the art as HALS
(Hindered Amine Light Stabilizers), and UV stabilizers,
such as those available with trademark TINUVIN from
Ciba Specialty Chemicals, or other additives familiar
to the person skilled in the art in the formulation of
adhesives, potting compositions, or
sealing
compositions. Compositions which comprise no solvents
and/or plasticizers are preferred.
The compositions feature firstly high toughness and
secondly good processing properties, for example low
melt viscosity, while simultaneously featuring high
melting point after polymerization.
The composition is preferably prepared via a process
encompassing the following steps:
- formation of a premix AC of toughness improver
C and of the compound A which has at least two
glycidyl ether groups,
- addition of the mixed premix AC to the
macrocyclic poly(a,w-alkylene terephthalate) or
macrocyclic poly(a,o-alkylene 2,6-
naphthalenedicarboxylate) which has been mixed

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with the organotin catalyst or organotitanium
catalyst.
The linear or branched polyester B is preferably
prepared at a temperature of from 160 C to 220 C, in
particular from 160 C to 200 C, in the presence of the
premix AC, and also of an organotin or organotitanium
catalyst, via ring-opening polymerization, starting
from a macrocyclic poly(a,w-alkylene terephthalate) or
from a macrocyclic poly(a,w-alkylene 2,6-
naphthalenedicarboxylate).
The premix AC is preferably prepared via mixing to
incorporate the toughness improver C into the compound
A. This premixing preferably takes place at an elevated
temperature with high shear forces. If the compound is
a solid resin, the premix AC can also be prepared via
mixing of compound A in powder form, or by means of
extrusion.
It is preferable to begin by preparing a homogeneous
premix of macrocyclic poly(a,o-alkylene terephthalate)
or of macrocyclic poly(a,w-alkylene 2,6-
naphthalenedicarboxylate) and organotin catalyst or
organotitanium catalyst at temperatures markedly below
the polymerization temperature, e.g. in a twin-screw
extruder, and then, after cooling, to grind the
material to give a powder. The premix AC is then
preferably added, with stirring, to a pulverulent
premix of macrocyclic poly(a,o-alkylene terephthalate)
or macrocyclic poly(a,o-alkylene 2,6-
naphthalenedicarboxylate) and organotin or
organotitanium catalyst at room temperature, and either
charged in powder form to a mold or heated to the
melting point of the macrocycle at from 160 to 180 C
and then charged in the form of liquid mixture to the
mold. Ring-opening polymerization then takes place at
temperatures above 180 C.

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However, it is also possible to premix the mixture
composed of AC, for example, in an extruder at
temperatures below 140 C, and cool, grind, and store
it, or else to cool the mixture prepared in the melt,
and comminute and store it.
It is preferable that further use of the composition
takes place before the final degree of polymerization
is reached.
This type of preparation process has the advantage of
permitting unexpectedly good and homogeneous
incorporation of the toughness improver C, thus
permitting use of solvents or plasticizer to be omitted
or at least greatly reduced. A particular effect of
this is to avoid unnecessary lowering of the melting
point of the composition.
In one embodiment of the present invention, the
composition described is used for production of
composite products, in particular of nanocomposite
materials (nanocomposites).
These composite products comprise at least one
composition described above, and also fibers. The
fibers are in turn fibers selected from the group
consisting of glass fibers, metal fibers, carbon
fibers, aramid fibers, mineral fibers, plant fibers,
and mixtures thereof. Preferred fibers are carbon
fibers or metal fibers. Steel fibers are particularly
preferred. It is also possible that various types of
fibers are simultaneously present in the composite
product. The form in which the fibers are present can
be that of short or long fibers, and specifically that
of individual fibers or of rovings. Other forms in
which the fibers can be present are that of knits,
scrims, or wovens. The orientation of the fibers can be
monodirectional or random. In one particularly
preferred embodiment, the fibers present take the form

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of monodirectional fiber layers. It is also possible
for a plurality of layers of these knits, scrims, or
wovens to be present in a composite product. The fibers
used, and the precise nature of orientation of the
fibers, depend greatly on the geometry of the composite
product and on the requirements placed upon the
composite product in relation to mechanical loading.
The proportion of fibers in the composite product is
preferably from 30 to 65% by volume, based on the
volume of the composite product.
Various processes can be used in production of the
composite product. For example, continuous profiles can
be produced, in particular with sheet-like shape, by
continuous unwinding from rolls of a plurality of
rovings or of one or more fiber wovens, fiber scrims,
or fiber knits, and drawing the fibers through a heated
mold in which the molten composition is applied to the
fibers, and penetrates the fibers. In one embodiment,
the mold has an outlet through which the composite
product is continuously discharged during cooling. In
another embodiment, this mold likewise has an outlet
through which the composite product is continuously
discharged, but it is compacted in a further step
downstream by means of presses, preferably heated
presses, and, if necessary, converted to the desired
cross-sectional geometry by means of a mask. In a
cooling zone which follows, the composite product thus
produced is cooled to room temperature. Finally, the
continuous profile is rolled up or cut to length. These
continuous profiles have particularly good suitability
as reinforcement profiles, in particular as
reinforcement sheets such as those used for the static
reinforcement of construction works. These
reinforcement profiles are advantageously bonded by
means of adhesive to the structure requiring
reinforcement, by a method which forces these two
components together. Particularly preferred fibers

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which can be used for this are carbon fibers and glass
fibers.
Composite products can moreover be filled with the
composition by means of molds in which fibers are laid.
The final shape can be achieved by compression and
forming. The processes used for this are very well
known to the person skilled in the art and also
include, in particular, RIM and RTM processes, inter
alia.
Finally, especially when individual short fibers are
used, the fibers can be homogeneously mixed with the
molten composition, if appropriate during its
preparation, and compressed or cast into a mold, in
order to form a composite product.
The process used and the nature of the fiber
reinforcement depend greatly on the requirements placed
upon the composite product.
The inventive composite products are versatile. In
particular, they are used for the static reinforcement
of construction work or of a conveyance. They can
either be used together with other materials or used
alone. By way of example, mention may firstly be made
of reinforcement of bridges, or of tunnels, or of
buildings. Other examples are drivers' cabins,
bodywork, bumpers, wheel surrounds, spare-wheel
recesses, underbody and roof of automobiles, of rail
vehicles, or of buses or trucks. Further examples of
applications of these composite products are found in
sports and leisure items, such as tennis rackets,
bicycles, leisure boats. Preference is particularly
given to any of the applications in which the use of
these inventive composite products leads to a saving in
weight when comparison is made with use of conventional
materials.
Examples
Comparative example 1 (Ref. 1):

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20 g of macrocyclic polybutylene terephthalate (PBT)
are melted under nitrogen, with stirring at 160 C, with
1% of a titanate catalyst (PBT XB3 from Cyclics Corp.).
The melt is charged to a metal mold whose temperature
is controlled to 195 C, where it is polymerized for 30
minutes with exclusion of air. This gives a sheet of
dimensions 2*40*120 mm, from which test specimens are
milled for subsequent mechanical tests.
Comparative examples 2 to 4 (Ref. 2, Ref. 3, Ref. 4):
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted under nitrogen, with stirring at 160 C, with
1% of a titanate catalyst (PBT XB3 from Cyclics Corp.)
and 1.0 g of liquid epoxy resin (Araldite GY 250,
producer Huntsman). The melt is charged to a metal mold
whose temperature is controlled to 195 C, where it is
polymerized for 30 minutes with exclusion of air. This
gives a sheet of dimensions 2*40*120 mm, from which test
specimens are milled for subsequent mechanical tests
(Ref. 2).
An analogous method is used for the experiments for
Ref. 3 with 1.0 g of Araldite MY 790 (distilled, pure
bisphenol A diglycidyl ether, producer Huntsman) and
for Ref. 4 with 1.0 g of Araldite CY 179 (3,4-
epoxycyclohexyl 3,4-
epoxycyclohexanecarboxylate,
producer Huntsman).
Comparative example 5 (Ref. 5):
19.6 g of macrocyclic polybutylene terephthalate (PBT)
are melted under nitrogen, with stirring at 175 C, with
1% of a titanate catalyst (PBT XB3 from Cyclics Corp.)
and 0.4 g of Tixogel VZ (cation-exchanged bentonite,
producer Stdchemie) is admixed. The resultant solution
is charged for polymerization to a metal mold which is
temperature-controlled to 195 C, where it is
polymerized for 30 minutes with exclusion of air. This

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gives a sheet of dimensions 2*40*120 mm, from which test
specimens are milled for subsequent mechanical tests.
Comparative example 6 (Ref. 6):
Comparative example 6 (Ref. 6) is identical with
Comparative example 5 (Ref. 5) except that twice the
content of Tixogel VZ was used, i.e. 0.8 g for 19.2 g
of PBT. However, it was found here that this high
concentration of cation-exchanged lamellar mineral
could not then be taken up homogeneously. No mechanical
properties were therefore determined.
Inventive example 1 (1):
g of SBM AF-X M22 (triblock copolymer composed of
15 styrene, butadiene, and methyl methacrylate in a ratio
of 1:1:1, molecular weight 20 000 daltons, producer
Arkema) ("SBM") are dissolved in 80 g of technical-
grade bisphenol A diglycidyl ether (Araldite0 GY 250,
Huntsman) under nitrogen, with stirring at 205 C. After
20 cooling to room temperature, a clear, highly viscous
solution (AC) is obtained.
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 175 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the solution of SBM in
liquid resin (AC) is admixed. The resultant solution is
charged for polymerization to a metal mold which is
temperature-controlled to 195 C, where it is
polymerized for 30 minutes with exclusion of air. This
gives a sheet of dimensions 2*40*120 mm, from which test
specimens are milled for subsequent mechanical tests.
Inventive example 2 (2):
A reactive liquid rubber ("RLR") was prepared as
follows:
200 g of PolyTHF 2000 (OH number 57.5 mg/g of KOH)
were dried at 100 C in vacuo for 30 minutes. 47.5 g of
IPDI and 0.04 g of dibutyltin dilaurate were then

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added. The reaction was conducted in vacuo at 90 C to
constant NCO content of 3.58% after 2.5 h (theoretical
NCO content: 3.70%). 118.0 g of
technical-grade
trimethylolpropane glycidyl ether (Araldite DY-T,
producer Huntsman, OH content 1.85 equivalents/kg) were
then added. Stirring was continued at 90 C in vacuo
until NCO content had fallen below 0.1%, after a
further 3 h. This gave a clear product whose epoxy
content was 2.50 eq/kg.
25 g of the resultant reactive liquid rubber (RLR1) are
diluted with 75 g of technical-grade bisphenol A
diglycidyl ether (Araldite GY 250, Huntsman).
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 175 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the solution of RLR1 in
liquid resin (AC) is admixed. The resultant solution is
charged for polymerization to a metal mold which is
temperature-controlled to 195 C, where it is
polymerized for 30 minutes with exclusion of air.
Inventive example 3 (3):
50 g of the reactive liquid rubber (RLR1) described in
Inventive example 2 are diluted with 50 g of technical-
grade bisphenol A diglycidyl ether (Araldite GY 250,
Huntsman). 19.0 g of macrocyclic
polybutylene
terephthalate (PBT) are melted in an oil bath under
nitrogen, with stirring at 175 C, with 1% of a titanate
catalyst (PBT XB3 from Cyclics Corp.), and 1 g of the
solution of RLR1 in liquid resin (AC) is admixed. The
resultant solution is charged for polymerization to a
metal mold which is temperature-controlled to 195 C,
where it is polymerized for 30 minutes with exclusion
of air.
Inventive example 4 (4):
30 g of Cloisite 93A
(cation-exchanged
montmorillonite, producer Southern Clay Products) are

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stirred at 90 C with 70 g of technical-grade bisphenol
A diglycidyl ether (Araldite GY 250, Huntsman). After
one hour, the product is a clear viscous mass.
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 160 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the swollen phyllosilicate
in liquid resin (AC) is admixed. The resultant solution
is charged for polymerization to a metal mold which is
temperature-controlled to 195 C, where it is
polymerized for 30 minutes with exclusion of air.
Inventive example 5 (5):
A reactive liquid rubber ("RLR") was prepared as
follows:
An isocyanate-terminated prepolymer is prepared at 90 C
from 48.19 g (217 mmol) of isophorone diisocyanate
(IPDI) and 200 g (100 mmol) of
dihydroxypolybutylene oxide (PolyTHFO 2000, producer
BASF) with 25 mg of dibutyltin dilaurate as catalyst.
11.1 g of monohydroxy-terminated poly(dimethylsiloxane)
(Silaplan FM 041, molecular weight 1000
daltons,
producer Itochu), and also 109 g of a technical-grade
trimethylolpropane glycidyl ether (Araldite DY-T,
producer Huntsman, OH content 1.85 equivalents/kg) were
then added, with stirring. Isocyanate concentration is
less than 0.1% after 60 minutes. The resultant reactive
liquid rubber (RLR2) is diluted with 100 g of liquid
epoxy resin (Araldite GY 250, producer Huntsman).
50 g of Cloisite 30B (cation-
exchanged
montmorillonite, producer Southern Clay Products) are
admixed at 90 C with 150 g of this reactive liquid
rubber diluted with liquid epoxy resin, and swollen to
give a clear viscous paste. (AC)
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 175 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the RLR2/nanoclay/liquid

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resin premix (AC) described above is admixed. The
resultant solution is charged for polymerization to a
metal mold which is temperature-controlled to 195 C,
where it is polymerized for 30 minutes with exclusion
of air. This gives a sheet of dimensions 2*40*120 mm,
from which test specimens are milled for subsequent
mechanical tests.
Inventive example 6 (6):
An isocyanate-terminated prepolymer is prepared at 90 C
from 48.19 g (217 mmol) of isophorone diisocyanate
(IPDI) and 200 g (100 mmol) of a, co-
dihydroxypolybutylene oxide (PolyTHFO 2000, producer
BASF) with 25 mg of dibutyltin dilaurate as catalyst.
The following are then added, with stirring: first
4.11 g (22.2 mmol) of n-dodecylamine, and then 109 g of
a technical-grade trimethylolpropane glycidyl ether
(Araldite DY-T, producer Huntsman, OH content 1.85
equivalents/kg). Isocyanate concentration is smaller
than 0.1% after 60 minutes.
40 g of the resultant reactive liquid rubber (RLR3) are
diluted with 40 g of technical-grade bisphenol A
diglycidyl ether (Araldite GY 250, Huntsman) and
heated to 90 C, with stirring. 20 g of Cloisite 93A
(cation-exchanged montmorillonite, producer Southern
Clay Products) are then added and swollen to give a
clear viscous paste. (AC)
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 175 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the RLR3/nanoclay/liquid
resin premix (AC) described above is admixed. The
resultant solution is charged for polymerization to a
metal mold which is temperature-controlled to 195 C,
where it is polymerized for 30 minutes with exclusion
of air.

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Inventive example 7 (7):
20 g of RLR3 (as described in Inventive example 6) are
diluted with 60 g of technical-grade bisphenol A
diglycidyl ether (Araldite0 GY 250, Huntsman) and
heated to 90 C, with stirring. 20 g of Cloisite0 93A
(cation-exchanged montmorillonite, producer Southern
Clay Products) are then added and swollen to give a
clear viscous paste. (AC)
19.0 g of macrocyclic polybutylene terephthalate (PBT)
are melted in an oil bath under nitrogen, with stirring
at 175 C, with 1% of a titanate catalyst (PBT XB3 from
Cyclics Corp.), and 1 g of the RLR3/nanoclay/liquid
resin premix (AC) described above is admixed. The
resultant solution is charged for polymerization to a
metal mold which is temperature-controlled to 195 C,
where it is polymerized for 30 minutes with exclusion
of air.
Comparative example 7 (Ref. 7):
Comparative example 7 (Ref. 7) is identical with
Inventive example 1 (1) except that an identical amount
of Araldite0 CY 179 (3,4-epoxycyclohexyl 3,4-
epoxycyclohexanecarboxylate, producer Huntsman) was
used instead of Araldite GY 250. The test specimens
thus produced were so brittle that they broke apart
during milling and could not be tested.

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A C C/(A+C)
Additive for PBT (B)
[%]* [%]* [%]
Ref.1 -
Ref.2 GY 250 (21) 5
Ref.3 MY 790 (A) 5
Ref.4 CY 179 (-)
Ref.5 Tixogel VZ(C/) 2 100
Ref.6 Tixogel VZ(C/) 4 100
CY 179 (-)
Ref.7 1
SBM (C3)
GY 250 (A)
4 1 20
SBM (C3)
GY 250 (A)
2 3.75 1.25 25
RLR1 (C2)
GY 250 (.74.)
3 2.5 2.5 50
RLR1 (C2)
GY 250 (24.)
4 3.5 1.5 30
Cloisite 93A (C1)
GY 250 (A)
Cloisite 30 B (C/) 0.8 4.2 84
RLR2 (C2)
GY 250 (A)
6 Cloisite 93A (C/) 2 3 60
RLR3 (C2)
GY 250 (A)
7 Cloisite 93A (C/) 3 2 40
RLR3 (C2)
Table 1: Composition of examples.
based on the weight of the composition

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Test methods
Flexural strength, flexural strain, and flexural
modulus were measured to DIN EN ISO 178 (determination
of flexural properties) on a 1185-5500R Instron tester
at 2 mm/min at 23 C, 50% rel. humidity.
Flexural Flexural strain Flexural modulus
strength [MPa] [9,5] [MPa]
Ref.1 51.0 1.6 3175
Ref.2 62.7 2.6 2704
Ref.3 55.8 2.0 2772
Ref.4 14.0 0.5 2614
Ref.5 25.87 0.8 2795
Ref.6 n.m.** n.m.** n.m.**
Ref.7 n.m.** n.m.** n.m.**
1 73.5 3.3 2684
2 77.41 4.65 2267
3 64.58 3.55 2024
4 85.82 4.5 2519
5 86.9 4.1 2709
6 81.73 4.38 2458
7 79.86 3.79 2395
Table 2: Mechanical properties of examples.
n.m. = not measurable
Table 2 shows that formulations with technical-grade
liquid epoxy resin (Araldite GY 250) which has a
proportion of hydroxy-functional oligomers (s > 0 in
formula (I)) exhibit better mechanical properties than
those exhibited when using bisphenol A diglycidyl ether
having no hydroxy groups (Araldite MY 790) (Ref. 2 and
Ref. 3). Table 2 moreover shows that when compounds
having two glycidyl ether groups, Araldite GY 250 and
Araldite MY 790, are compared with Araldite CY 179
(3,4-epoxycyclohexylmethyl 3,4-
epoxycyclohexane-

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carboxylate Ref. 4), there is a pronounced improvement
in mechanical properties.
The results from the inventive compositions moreover
show greatly increased values for mechanical
properties. It is also noticeable that the inventive
compositions simultaneously exhibit higher values for
flexural strength and for flexural strain when compared
with the comparative examples.
In the inventive compositions it is possible to achieve
higher contents of toughness improvers than in the
comparative examples. For example, mixing to achieve
homogeneous incorporation using toughness improver
content of 4% by weight in compositions is impossible
to achieve Ref. 6, whereas in 5 this is indeed possible
without difficulty using even higher content.
Finally, it was found that the inventive examples have
better toughness properties than the comparative
examples.