Alloy material, method for producing the same, and automotive trim part

Abstract

The application provides an alloy material, a preparation method thereof and an automobile trim part, and the alloy material is prepared by melt extrusion of raw materials including 50-80 parts by weight of aliphatic polycarbonate, 5-20 parts by weight of styrene-acrylonitrile copolymer, 8-40 parts by weight of polymethyl methacrylate and 1-5 parts by weight of a compatibilizer; the preparation method comprises the following steps: (1) uniformly mixing raw materials of the alloy material to obtain a premix; (2) melt extruding the obtained premix in a double-screw extruder to obtain the alloy material; and the alloy material prepared by the application has higher surface hardness and excellent high-gloss black performance.

Description

Technical Field

[0001] This invention relates to the field of alloy materials technology, and in particular to an alloy material, its preparation method, and automotive trim parts. Background Technology

[0002] Lightweighting is a major trend in the automotive industry, aligning with current requirements for emission reduction, energy conservation, efficiency improvement, and range extension. This trend has led to increased demand for automotive plastic components. Currently, modified plastics, due to their significant advantages such as low cost and high performance, are the second most used material in automobiles after metals. High-gloss piano black trim is generally considered to enhance the aesthetics of the entire automotive interior, with applications ranging from high-end luxury models to economy vehicles. However, the fact that high-gloss injection-molded materials are susceptible to scratches limits their application.

[0003] Therefore, developing an alloy material that achieves both aesthetic decoration and scratch resistance has a promising market prospect. Summary of the Invention

[0004] To address the problems of poor scratch resistance and low gloss black performance of high-gloss injection molded materials in existing technologies, this invention provides an alloy material, its preparation method, and automotive trim parts. The prepared alloy material has high surface hardness, which effectively improves its scratch resistance, and also has a low L-value, giving it excellent high-gloss black performance.

[0005] The objective of this invention is mainly achieved through the following technical solutions.

[0006] In a first aspect, the present invention provides an alloy material, which is obtained by melt extrusion of a raw material comprising 50-80 parts by weight of aliphatic polycarbonate, 5-20 parts by weight of styrene-acrylonitrile copolymer, 8-40 parts by weight of polymethyl methacrylate and 1-5 parts by weight of compatibilizer.

[0007] Preferably, the raw material of the alloy material includes 55-65 parts by weight of aliphatic polycarbonate.

[0008] And / or, the raw materials of the alloy material include 6-10 parts by weight of styrene-acrylonitrile copolymer.

[0009] And / or, the raw material of the alloy material includes 10-12 parts by weight of polymethyl methacrylate.

[0010] And / or, the raw materials of the alloy material include 2-4 parts by weight of a compatibilizer.

[0011] And / or, the raw materials of the alloy material further include 0.1-0.6 parts by weight of antioxidant, preferably 0.3-0.5 parts by weight of antioxidant.

[0012] And / or, the raw materials of the alloy material further include 0.1-0.5 parts by weight of a release agent, preferably 0.1-0.3 parts by weight of a release agent.

[0013] And / or, the raw materials of the alloy material further include 1-10 parts by weight of toughening agent, preferably 6-10 parts by weight of toughening agent.

[0014] And / or, the raw materials of the alloy material further include 1-4 parts by weight of black masterbatch, preferably 1-3 parts by weight of black masterbatch.

[0015] And / or, the raw materials of the alloy material further include 0.5-12 parts by weight of a scratch-resistant agent, preferably 5-10 parts by weight of a scratch-resistant agent.

[0016] Preferably, the total amount of the polymethyl methacrylate and the scratch-resistant agent is 15-25 parts by weight, more preferably 18-22 parts by weight.

[0017] Preferably, the weight ratio of the polymethyl methacrylate to the scratch-resistant agent is 0.5-4:1, more preferably 1-3:1.

[0018] And / or, the weight ratio of the aliphatic polycarbonate to the toughening agent is 5-10:1, more preferably 7-8:1.

[0019] And / or, the weight ratio of the styrene-acrylonitrile copolymer to the compatibilizer is 1-5:1, more preferably 3-5:1.

[0020] Preferably, the aliphatic polycarbonate has a melt index of 8-18 g / 10 min at 230°C and a load of 2.16 kg.

[0021] Preferably, the aliphatic polycarbonate has a weight-average molecular weight of 20,000-40,000 g / mol.

[0022] Preferably, the aliphatic polycarbonate is selected from at least one of sorbitol polycarbonate, isosorbitol polycarbonate, citric acid alcohol polycarbonate and isosorbide dinitrate polycarbonate.

[0023] Preferably, the polymethyl methacrylate has a melt index of 2-20 g / 10 min at 230°C and a load of 3.8 kg.

[0024] Preferably, the polymethyl methacrylate has a weight-average molecular weight of 60,000-400,000 g / mol.

[0025] Preferably, the styrene-acrylonitrile copolymer has a melt index of 15-45 g / 10 min at 220°C and a 10 kg load.

[0026] Preferably, the weight-average molecular weight of the styrene-acrylonitrile copolymer is 100,000-250,000 g / mol.

[0027] Preferably, the weight ratio of styrene units to acrylonitrile units in the styrene-acrylonitrile copolymer is 1:1-6, more preferably 1:1.5-3.

[0028] Preferably, the toughening agent is a core-shell copolymer, and more preferably a core-shell acrylate copolymer.

[0029] Preferably, the core-shell type acrylate copolymer has a particle size of 1-10 μm, more preferably 1-2 μm.

[0030] Preferably, the core of the core-shell acrylate copolymer is selected from at least one of butadiene rubber, acrylate rubber and silicone rubber.

[0031] And / or, the shell of the core-shell acrylate copolymer is polymethyl methacrylate and polystyrene, or polymethyl methacrylate.

[0032] And / or, the weight ratio of the core to the shell of the core-shell acrylate copolymer is 1-9:1, preferably 1.5-4:1.

[0033] Preferably, the compatibilizer is a maleic anhydride copolymer.

[0034] Preferably, the weight-average molecular weight of the maleic anhydride copolymer is 5500-200000 g / mol.

[0035] Preferably, the maleic anhydride copolymer is selected from at least one of styrene-maleic anhydride copolymer, styrene-acrylonitrile-maleic anhydride copolymer, and methyl methacrylate-maleic anhydride copolymer.

[0036] Preferably, the content of polymeric units formed by maleic anhydride in the maleic anhydride copolymer is 0.5-20 wt%.

[0037] Preferably, the scratch-resistant agent is a methacrylate copolymer.

[0038] Preferably, the scratch-resistant agent is selected from at least one of methyl methacrylate-ethyl methacrylate copolymer, methyl methacrylate-butyl methacrylate copolymer, and ethyl methacrylate-butyl methacrylate.

[0039] Preferably, the scratch-resistant agent has a weight-average molecular weight of 20,000-50,000 g / mol.

[0040] Preferably, the carbon black content of the black masterbatch is 50-60 wt%.

[0041] Preferably, the carbon black particle size distribution in the black masterbatch is 10-50 nm, and more preferably 20-30 nm.

[0042] Preferably, the black masterbatch is a styrene-acrylonitrile copolymer carrier black masterbatch.

[0043] Preferably, the antioxidant is selected from hindered phenolic antioxidants and / or phosphite antioxidants.

[0044] Preferably, the hindered phenolic antioxidant is selected from at least one of pentaerythritol ester [β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octadecyl ester of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazine, and 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene.

[0045] Preferably, the phosphite-type antioxidant is selected from at least one of tris[2,4-di-tert-butylphenyl] phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, and bis(2,6-di-tert-butyl-4-methylbenzyl) pentaerythritol diphosphate.

[0046] Preferably, the release agent is selected from at least one of stearamide, hydrocarbon and fatty acid release agents.

[0047] Preferably, the fatty acid release agent is selected from at least one of butyl stearate, calcium stearate, methyl stearate, and pentaerythritol tetrastearate.

[0048] Preferably, the notched impact strength of the alloy material is 30-56 kJ / m. 2 .

[0049] Preferably, the heat distortion temperature of the alloy material is 88-96℃.

[0050] Preferably, the flexural modulus of the alloy material is 2550-3000 MPa.

[0051] In a second aspect, the present invention provides a method for preparing the alloy material described in the first aspect, the method comprising:

[0052] Step (1): Mix the raw materials of the alloy material evenly to obtain a premix.

[0053] Step (2): Add the obtained premix to a twin-screw extruder for melt extrusion to obtain the alloy material.

[0054] Preferably, the twin-screw extruder has a screw length-to-diameter ratio of 32-40:1 and a screw temperature of 170-270℃.

[0055] And / or, in step (2), melt extrusion is performed under conditions of -0.075MPa to -0.08MPa.

[0056] Preferably, the screw temperature includes: zone 1 feeding zone temperature of 150-170℃, zone 2 pressure building zone temperature of 210-250℃, zone 3 pressure building zone temperature of 210-250℃, zone 4 melting temperature of 210-250℃, zone 5 exhaust temperature of 210-250℃, zone 6 conveying temperature of 210-250℃, zone 7 conveying temperature of 210-250℃, zone 8 pressure building temperature of 200-240℃, zone 9 devolatilization zone temperature of 210-250℃, zone 10 pressure building zone temperature of 200-240℃, die temperature of 200-240℃, and die head temperature of 190-230℃.

[0057] Thirdly, the present invention provides an automotive trim component, the automotive trim component comprising a component formed from the alloy material described in the first aspect or the alloy material prepared by the preparation method described in the second aspect.

[0058] Preferably, the automotive trim includes automotive interior trim and automotive exterior trim.

[0059] This invention relates to an alloy material, its preparation method, and automotive trim parts. The alloy material prepared by this method can achieve a surface hardness of 3H, which effectively improves the scratch resistance of the alloy material. Moreover, the color L value can be as low as 25.9, exhibiting good high-gloss black properties, as well as good mechanical properties. It is very suitable for preparing automotive trim parts with high requirements for high-gloss black properties. Detailed Implementation

[0060] Researchers discovered that combining aliphatic polycarbonate and polymethyl methacrylate (PMMA) can give the alloy material higher surface hardness and improved scratch resistance. It is believed that differences in compatibility and refractive index between different materials cause light scattering at the interface, leading to decreased transparency and a whitened surface, thus reducing the high-gloss blackness (increased chromaticity value). To achieve a high-gloss blackness alloy, less light scattering within the alloy is desirable. A transparent alloy reduces internal light scattering. The refractive index difference between aliphatic polycarbonate and PMMA is 0.0059; when the refractive index difference between the two phases is less than or equal to 0.008, the blend is transparent. Further research revealed that although the close refractive index difference between aliphatic polycarbonate and PMMA results in good transparency, the high-gloss performance of the resulting alloy is still relatively poor, possibly due to their poor compatibility. Based on this discovery, the inventors creatively added styrene-acrylonitrile copolymer and compatibilizer to polymethyl methacrylate and styrene-acrylonitrile copolymer in specific amounts to form an island structure with aliphatic polycarbonate as the continuous phase and polymethyl methacrylate as the island phase. By relying on the addition of styrene-acrylonitrile copolymer resin and compatibilizer to improve the compatibility between the two phases, the high-gloss performance of the alloy material was improved.

[0061] Toughening agents are used to ensure the mechanical properties of alloy materials. Based on the use of polymethyl methacrylate (PMMA) in combination with scratch-resistant agents, excellent surface hardness is imparted to the material without affecting its appearance. Furthermore, the use of compatibilizers can further improve the transparency of the alloy material and enhance its high-gloss performance. Moreover, the inventors unexpectedly discovered that the combined use of aliphatic polycarbonate, PMMA, and scratch-resistant agents can achieve a balance between excellent surface hardness and high-gloss performance.

[0062] Based on the above research, in a first aspect, the present invention provides an aliphatic polycarbonate / polymethyl methacrylate / styrene-acrylonitrile copolymer alloy material, wherein the alloy material is obtained by melt extrusion of a raw material comprising 50-80 parts by weight of aliphatic polycarbonate, 5-20 parts by weight of styrene-acrylonitrile copolymer, 8-40 parts by weight of polymethyl methacrylate and 1-5 parts by weight of compatibilizer.

[0063] Through further research, the inventors discovered that aliphatic polycarbonate, styrene-acrylonitrile copolymer, polymethyl methacrylate, and compatibilizer, within a specific dosage range, can ensure the formation of an island structure in the alloy material, with aliphatic polycarbonate as the marine phase and polymethyl methacrylate and styrene-acrylonitrile copolymer as the island phases. The three phase components exhibit good compatibility, which improves the surface hardness and mechanical properties of the alloy material while ensuring its excellent high-gloss blackness.

[0064] In a preferred embodiment of the present invention, the raw materials of the alloy material include 55-65 parts by weight of aliphatic polycarbonate; and / or, the raw materials of the alloy material include 6-10 parts by weight of styrene-acrylonitrile copolymer; and / or, the raw materials of the alloy material include 10-12 parts by weight of polymethyl methacrylate; and / or, the raw materials of the alloy material include 2-4 parts by weight of compatibilizer.

[0065] In a preferred embodiment of the present invention, the raw materials of the alloy material include 0.1-0.6 parts by weight of antioxidant, preferably 0.3-0.5 parts by weight of antioxidant; the addition of a specific amount of antioxidant is beneficial to improving the stability of the high-gloss black performance of the alloy material.

[0066] In a preferred embodiment of the present invention, the raw material of the alloy material includes 0.1-0.5 parts by weight of a release agent, preferably 0.1-0.3 parts by weight of a release agent; the addition of a specific amount of release agent is beneficial to ensure smooth demolding of the alloy material during injection molding, and further reduces the uncertainty in the production and processing of the alloy material.

[0067] In a preferred embodiment of the present invention, the raw materials of the alloy material include 1-10 parts by weight of toughening agent, preferably 6-10 parts by weight of toughening agent; the addition of a specific amount of toughening agent also has a positive impact on improving the high-gloss black performance of the alloy material.

[0068] In this invention, a three-phase system of aliphatic polycarbonate, polymethyl methacrylate, and styrene-acrylonitrile copolymer, combined with a black masterbatch, can enable the alloy material to obtain excellent high-gloss black performance. In a preferred embodiment, the raw materials of the alloy material include 1-4 parts by weight of black masterbatch, preferably 1-3 parts by weight of black masterbatch.

[0069] In this invention, the high-gloss black performance is represented by the chromaticity L value, which is determined according to GB / T3979-2008 "Methods for measuring the color of objects". The smaller the chromaticity value, the darker the color.

[0070] In a preferred embodiment of the present invention, the raw materials of the alloy material include 0.5-12 parts by weight of a scratch-resistant agent, preferably 5-10 parts by weight of a scratch-resistant agent; the polymethyl methacrylate and the scratch-resistant agent, when used in combination, can effectively improve the surface hardness and high-gloss black performance of the alloy material, thereby avoiding the loss of high-gloss black performance of the alloy material surface due to friction.

[0071] In a more preferred embodiment of the present invention, the total amount of polymethyl methacrylate and the scratch-resistant agent is 15-25 parts by weight, more preferably 18-22 parts by weight; the specific amount of polymethyl methacrylate and scratch-resistant agent in the alloy material can further improve the surface hardness and high gloss black performance of the alloy material.

[0072] In a more preferred embodiment of the present invention, the weight ratio of the polymethyl methacrylate to the scratch-resistant agent is 0.5-4:1, more preferably 1-3:1.

[0073] In this invention, the aliphatic polycarbonate and the toughening agent are combined in specific amounts to enable the alloy material to have high notched impact strength, as well as good color L value and surface hardness. Preferably, the weight ratio of the aliphatic polycarbonate to the toughening agent is 5-10:1, more preferably 7-8:1.

[0074] In this invention, the styrene-acrylonitrile copolymer and the compatibilizer are combined in a specific amount, which not only ensures good compatibility between the three phases, but also effectively improves the surface hardness of the alloy material, while also taking into account excellent high-gloss black performance. Preferably, the weight ratio of the styrene-acrylonitrile copolymer to the compatibilizer is 1-5:1, more preferably 3-5:1.

[0075] In a preferred embodiment of the present invention, the aliphatic polycarbonate has a melt index of 8-18 g / 10 min at 230°C and 2.16 kg load, more preferably 12-16 g / 10 min.

[0076] In a preferred embodiment of the present invention, the aliphatic polycarbonate has a weight-average molecular weight of 20,000-40,000 g / mol, more preferably 25,000-27,000 g / mol.

[0077] In this invention, the aliphatic polycarbonate is prepared from biological raw materials or from fossil raw materials, and there is no particular limitation on this. In a preferred embodiment of this invention, the aliphatic polycarbonate is selected from at least one of sorbitol-type polycarbonate, isosorbitol-type polycarbonate, citric acid alcohol-type polycarbonate, and iso-idole-type polycarbonate, more preferably iso-idole-type polycarbonate.

[0078] In this invention, the aliphatic polycarbonate can be purchased from commercial products or obtained by self-preparation.

[0079] In a preferred embodiment of the present invention, the preparation method of the iso-idole-type polycarbonate is based on the preparation method disclosed in CN113336931B, and includes the following steps:

[0080] (1) The titanium catalyst is preheated to a catalyst hot phenol solution. The titanium catalyst is Ti(OCH(CH3)2)4 or Ti-salen. The concentration of the titanium catalyst is 4-8%. The preheating temperature is 48-55℃. The titanium catalyst is added when the reactor is heated to ≥50℃.

[0081] (2) The set amount of iso-idyl alcohol, diphenyl carbonate and titanium catalyst are placed in a reaction vessel and mixed. The molar ratio of iso-idyl alcohol to diphenyl carbonate is 1:(1-1.1). The amount of titanium catalyst added is 0.1-0.15 mol% of iso-idyl alcohol. While stirring, the temperature is raised to 228-240℃, and then the reaction is kept at a vacuum environment with a pressure of <5 kPa for 5-6.5 h.

[0082] (3) Before heating, nitrogen is used to replace the air inside the reactor and provides continuous protection during the reaction. The process pressure is controlled at 0.3-0.5 kPa. The reactor is heated to 100°C and stirred at a constant speed. The process of heating the reactor to 115-125°C takes 1.5-2.5 hours. After the reactor is heated to 170-185°C, it is kept at this temperature for 2-3 hours. During the reaction of iso-arthenol and diphenyl carbonate, the gas inside the reactor is continuously extracted.

[0083] (4) After the reaction is terminated, a quencher is added to the reaction vessel. The quencher is one or a mixture of two of Na2H2P2O7 and NaH2PO4. The amount of the quencher added is 0.14-0.16 mol% of iso-idiodine. After reacting for 10-15 min, the iso-idiodine type polycarbonate is obtained by filtration.

[0084] In a preferred embodiment of the present invention, the polymethyl methacrylate has a melt index of 2-20 g / 10 min at 230°C and 3.8 kg load, more preferably 8-18 g / 10 min.

[0085] In a preferred embodiment of the present invention, the polymethyl methacrylate has a weight-average molecular weight of 60,000-400,000 g / mol, preferably 200,000-300,000 g / mol.

[0086] In a preferred embodiment of the present invention, the styrene-acrylonitrile copolymer has a melt index of 15-45 g / 10 min at 220°C and a load of 10 kg, preferably 15-22 g / 10 min.

[0087] In a preferred embodiment of the present invention, the weight-average molecular weight of the styrene-acrylonitrile copolymer is 100,000-250,000 g / mol, preferably 140,000-160,000 g / mol.

[0088] In a preferred embodiment of the present invention, the weight ratio of styrene units to acrylonitrile units in the styrene-acrylonitrile copolymer is 1:1-6, preferably 1:1.5-3.

[0089] In a preferred embodiment of the present invention, the toughening agent is a core-shell copolymer, preferably a core-shell acrylate copolymer.

[0090] In a preferred embodiment of the present invention, the core-shell acrylate copolymer has a particle size of 1-10 μm, more preferably 1-2 μm. Using a toughening agent with this preferred particle size distribution not only ensures the mechanical properties of the material but also reduces its impact on the material's appearance, allowing the alloy material to still possess good high-gloss black properties.

[0091] In a preferred embodiment of the present invention, the core of the core-shell acrylate copolymer is selected from at least one of butadiene rubber, acrylate rubber and silicone rubber, more preferably butadiene rubber.

[0092] And / or, the shell of the core-shell acrylate copolymer is polymethyl methacrylate and polystyrene, or polymethyl methacrylate, more preferably polymethyl methacrylate and styrene.

[0093] In a preferred embodiment of the present invention, the shell of the core-shell acrylate copolymer is polymethyl methacrylate and polystyrene, and the core is butadiene rubber. More preferably, the weight ratio of polymethyl methacrylate to polystyrene in the polymethyl methacrylate and polystyrene composition is 1-1.5:1.

[0094] In a preferred embodiment of the present invention, the weight ratio of the core to the shell of the core-shell acrylate copolymer is 1-9:1, preferably 1.5-4:1.

[0095] In a preferred embodiment of the present invention, the compatibilizer is a maleic anhydride copolymer, more preferably, the weight-average molecular weight of the maleic anhydride copolymer is 5500-200000 g / mol, and more preferably 140000-180000 g / mol.

[0096] In a preferred embodiment of the present invention, the maleic anhydride copolymer is selected from at least one of styrene-maleic anhydride copolymer, styrene-acrylonitrile-maleic anhydride copolymer, and methyl methacrylate-maleic anhydride copolymer, more preferably styrene-maleic anhydride copolymer.

[0097] In a preferred embodiment of the present invention, the content of polymeric units formed by maleic anhydride in the maleic anhydride copolymer is 0.5-20 wt%, more preferably 12-19 wt%.

[0098] In a preferred embodiment of the present invention, the scratch-resistant agent is a methacrylate copolymer.

[0099] In a preferred embodiment of the present invention, the scratch-resistant agent is selected from at least one of methyl methacrylate-ethyl methacrylate copolymer, methyl methacrylate-butyl methacrylate copolymer, and ethyl methacrylate-butyl methacrylate, more preferably methyl methacrylate-ethyl methacrylate copolymer and / or methyl methacrylate-butyl methacrylate copolymer.

[0100] In a preferred embodiment of the present invention, the scratch-resistant agent has a weight-average molecular weight of 20,000-50,000 g / mol, more preferably 28,000-35,000 g / mol. Using this preferred scratch-resistant agent, it can work in conjunction with polymethyl methacrylate to effectively improve the hardness of the alloy material without affecting its high black gloss performance.

[0101] The three-phase alloy material formed by aliphatic polycarbonate, polymethyl methacrylate, and styrene-acrylonitrile copolymer in this invention exhibits good transparency. Based on the transparency of the alloy material, it can be used in conjunction with a black masterbatch to construct a high-gloss black system, further improving the high-gloss black performance of the alloy material. In a preferred embodiment of this invention, the carbon black content of the black masterbatch is 50-60 wt%; more preferably, the black masterbatch is a styrene-acrylonitrile copolymer carrier black masterbatch.

[0102] In a preferred embodiment of the present invention, the carbon black particle size distribution in the black masterbatch is 10-50 nm, preferably 20-30 nm.

[0103] In a preferred embodiment of the present invention, the antioxidant is selected from hindered phenolic antioxidants and / or phosphite antioxidants, more preferably hindered phenolic antioxidants and phosphite antioxidants. Using this preferred antioxidant ensures that the alloy material maintains stable high-gloss black properties during processing and guarantees that the alloy material retains its high-gloss black appearance for a long period during use.

[0104] In a preferred embodiment of the present invention, the hindered phenolic antioxidant is selected from at least one of pentaerythritol ester [β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octadecyl ester of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazine, and 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene, more preferably pentaerythritol ester [β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate].

[0105] In a preferred embodiment of the present invention, the phosphite-type antioxidant is selected from at least one of tris[2,4-di-tert-butylphenyl] phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, and bis(2,6-di-tert-butyl-4-methylbenzyl) pentaerythritol diphosphite, more preferably tris[2,4-di-tert-butylphenyl] phosphite.

[0106] In a preferred embodiment of the present invention, the release agent is selected from at least one of stearamide, hydrocarbon, and fatty acid release agents, more preferably a fatty acid release agent. Using this preferred release agent ensures smooth demolding of the alloy material, thereby reducing uncertainties in the alloy material's behavior during production and processing.

[0107] In a preferred embodiment of the present invention, the fatty acid release agent is selected from at least one of butyl stearate, calcium stearate, methyl stearate and pentaerythritol tetrastearate, more preferably pentaerythritol tetrastearate.

[0108] In this invention, the notched impact strength of the alloy material is 30-56 kJ / m. 2 The preferred value is 40-50 kJ / m 2 ; and / or, the heat distortion temperature of the alloy material is 88-96℃, preferably 88.6-93.6℃; and / or, the flexural modulus of the alloy material is 2550-3000MPa, preferably 2550-2900MPa.

[0109] In a second aspect, the present invention provides a composition for preparing the alloy material described in the first aspect, the composition comprising 50-80 parts by weight of aliphatic polycarbonate, 5-20 parts by weight of styrene-acrylonitrile copolymer, 8-40 parts by weight of polymethyl methacrylate and 1-5 parts by weight of compatibilizer.

[0110] In a preferred embodiment of the present invention, the composition further comprises 0.1-0.6 parts by weight of an antioxidant, 0.1-0.5 parts by weight of a release agent, 1-10 parts by weight of a toughening agent, 1-4 parts by weight of a black masterbatch, and 0.5-12 parts by weight of a scratch-resistant agent.

[0111] In this invention, the aliphatic polycarbonate, styrene-acrylonitrile copolymer, polymethyl methacrylate, compatibilizer, antioxidant, release agent, toughening agent, black masterbatch and scratch resistant agent described in the second aspect are the same as those in the first aspect.

[0112] Thirdly, the present invention provides a method for preparing the alloy material described in the first aspect, the method comprising:

[0113] Step (1): Mix the raw materials of the alloy material evenly to obtain a premix.

[0114] Step (2): Add the obtained premix to a twin-screw extruder for melt extrusion to obtain the alloy material.

[0115] In a preferred embodiment of the present invention, the twin-screw extruder has a screw length-to-diameter ratio of 32-40:1 and a screw temperature of 170-270℃.

[0116] In a preferred embodiment of the present invention, in step (2), melt extrusion is performed under conditions of -0.075MPa to -0.08MPa.

[0117] In this invention, there are no particular limitations on the structure and configuration of the twin-screw extruder; it is a conventional structure and configuration in the art. In a preferred embodiment of this invention, the screw temperatures include: zone 1 (feeding zone) temperature of 150-170℃, zone 2 (pressure building zone) temperature of 210-250℃, zone 3 (pressure building zone) temperature of 210-250℃, zone 4 (melting temperature) temperature of 210-250℃, zone 5 (exhaust temperature) temperature of 210-250℃, zone 6 (conveyor temperature) temperature of 210-250℃, zone 7 (conveyor temperature) temperature of 210-250℃, zone 8 (pressure building zone) temperature of 200-240℃, zone 9 (devouring zone) temperature of 210-250℃, zone 10 (pressure building zone) temperature of 200-240℃, die temperature of 200-240℃, and die head temperature of 190-230℃.

[0118] In one embodiment of the present invention, the processing method described in step (2) is a conventional processing method used in the art, which includes sequentially melting, plasticizing, shearing, dispersing, extruding, traction, cooling, granulating and homogenizing the obtained premix.

[0119] Fourthly, the present invention provides an automotive trim component comprising a part formed from the alloy material described in the first aspect, the composition described in the second aspect, or the alloy material prepared by the preparation method described in the third aspect.

[0120] In this invention, the component can be directly used as an automotive trim piece. For example, it can be used as the housing of an automotive air conditioner.

[0121] In this invention, the component can be an integral part of an automotive trim. For example, the center console housing of an automotive trim includes an instrument panel, a display screen, and a plastic panel formed of the alloy material.

[0122] In this invention, the automotive trim includes automotive interior trim and automotive exterior trim.

[0123] In this invention, the automotive interior parts refer to plastic components inside a car, including but not limited to steering wheel housings, air conditioning housings, ambient lighting interior panels, and center console housings.

[0124] In this invention, the automotive exterior parts refer to plastic components on the exterior of a vehicle, including but not limited to the grille and bumper covers on the front of the vehicle.

[0125] The following detailed description of preferred embodiments of the present invention illustrates the principles of the invention and is not intended to limit the scope of the invention.

[0126] The materials used in the following embodiments and comparative examples are as follows:

[0127] Iso-idol type polycarbonate: melt index of 15 g / 10 min at 230℃ and 2.16 kg load, and weight-average molecular weight of 25000 g / mol;

[0128] Prepared according to the method disclosed in Example 6 of CN113336931B:

[0129] 1. Raw material preparation: Accurately weigh 442.5g of isosorbide and 687.5g of diphenyl carbonate according to the molar ratio of isosorbide to diphenyl carbonate of 1:1.06; weigh 41.21g of titanium catalyst Ti(OCH(CH3)2) according to 0.14mol% of isosorbide; prepare 25.1mL of hot phenol solution of catalyst with a mass percentage concentration of 5% and a preheating temperature of 50℃; weigh quencher Na2H2P2O7 according to 0.15mol% of isosorbide.

[0130] 2. Reactor treatment: The air inside the reactor is replaced three times with nitrogen and continuous protection is provided. During the reaction process, a vacuum pump is used to continuously remove the gas from the reactor and control the gas pressure in the reactor to 0.35 kPa.

[0131] 3. Mixing reaction: Add iso-arthenol and diphenyl carbonate prepared in step 1 into a 1L reactor and mix. Heat to 50°C, add the hot phenol solution prepared in step 1 as catalyst, and continue heating the reactor. When the temperature reaches 100°C, start uniform stirring. When the temperature reaches 120°C, the entire melting process takes 2 hours.

[0132] The reactor was heated to 180°C for transesterification and held at that temperature for 2 hours. Finally, the temperature was increased to 230°C for polymerization and held at that temperature for 6 hours.

[0133] 4. Termination of reaction: After the polymerization reaction is completed, add the quencher prepared in step 1, react for 10 minutes, and filter while hot through a 70-mesh filter to remove the catalyst complex. The filter is made of stainless steel. After collecting the filtrate and cooling, iso-arthenol-type polycarbonate is obtained.

[0134] Isosorbide-based polycarbonate: melt index of 13 g / 10 min at 230 °C and 2.16 kg load, weight-average molecular weight of 26000 g / mol, purchased from Mitsubishi Chemical, Japan, grade D5360R;

[0135] Bisphenol A type polycarbonate (PC): melt index of 20 g / 10 min at 300℃ and 1.2 kg load, weight average molecular weight of 26000 g / mol; manufacturer is Ningbo Dafeng Jiangning New Material Technology Co., Ltd., grade 02-20;

[0136] Polymethyl methacrylate (PMMA): melt index of 16 g / min at 230℃ and 3.8 kg load, weight average molecular weight of 360,000 g / mol, purchased from Chi Mei Corporation, Taiwan, grade CM-211;

[0137] Styrene-acrylonitrile copolymer: melt index of 15 g / 10 min at 220℃ and 10 kg load, weight average molecular weight of 100,000 g / mol, weight ratio of styrene polymerization units to acrylonitrile polymerization units of 1:2, purchased from Formosa Plastics Corporation, Taiwan, grade NX3200;

[0138] #1 Toughening Agent: MBS type toughening agent (polymethyl methacrylate and polystyrene as shell, butadiene rubber as core, core to shell weight ratio of 2:1, polymethyl methacrylate to polystyrene weight ratio of 3:2), particle size of 1-1.8μm, manufactured by Kaneka Corporation of Japan, brand name M210;

[0139] #2 Toughening Agent: ACR toughening agent (polymethyl methacrylate shell, acrylic rubber core, core to shell weight ratio of 3:1), particle size of 3-5μm, manufactured by Kaneka Corporation of Japan, brand name M577;

[0140] Antioxidants: Hindered phenolic antioxidant 1010 and phosphite antioxidant 168, manufactured by BASF, are mixed in a 1:1 weight ratio.

[0141] Release agent: Pentaerythritol tetrastearate, manufactured by Shanghai Minke New Material Technology Co., Ltd., brand name PETS-1;

[0142] Compatibilizer: Styrene-maleic anhydride copolymer, manufactured by Jiaxing Huawen Chemical Co., Ltd., brand name SMA-700, maleic anhydride content is 18wt%, weight average molecular weight is 160000g / mol;

[0143] Scratch-resistant agent: methyl methacrylate-ethyl methacrylate copolymer, manufactured by Mitsubishi Rayon Co., Ltd. of Japan, with a weight-average molecular weight of 28,000 g / mol, and grade H880;

[0144] Black Masterbatch: The manufacturer is Ningbo Masterbatch Co., Ltd., the carbon black particle size is 20nm, the carbon black content is 55wt%, and the grade is AS336.

[0145] Example 1

[0146] Step (1): Mix 60 parts by weight of iso-iso ...

[0147] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0148] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0149] Example 2

[0150] Step (1): Mix 60 parts by weight of iso-iso ...

[0151] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0152] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0153] Example 3

[0154] Step (1): Mix 55 parts by weight of iso-iso ...

[0155] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0156] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 32:1; zone 1 feed temperature 150℃; zone 2 pressure build-up temperature 210℃; zone 3 pressure build-up temperature 210℃; zone 4 melt temperature 210℃; zone 5 exhaust temperature 210℃; zone 6 conveying temperature 210℃; zone 7 conveying temperature 210℃; zone 8 pressure build-up temperature 200℃; zone 9 devolatilization temperature 230℃; zone 10 pressure build-up temperature 220℃; die temperature 220℃; and die head temperature 210℃. The vacuum negative pressure is -0.075MPa.

[0157] Example 4

[0158] Step (1): Mix 65 parts by weight of iso-iso ...

[0159] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0160] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 32:1; zone 1 feed temperature 170℃; zone 2 pressure build-up temperature 230℃; zone 3 pressure build-up temperature 230℃; zone 4 melt temperature 230℃; zone 5 exhaust temperature 230℃; zone 6 conveying temperature 230℃; zone 7 conveying temperature 230℃; zone 8 pressure build-up temperature 220℃; zone 9 devolatilization temperature 210℃; zone 10 pressure build-up temperature 200℃; die temperature 200℃; and die head temperature 190℃. The vacuum negative pressure is -0.075MPa.

[0161] Example 5

[0162] Step (1): Mix 50 parts by weight of iso-iso ...

[0163] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0164] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0165] Example 6

[0166] Step (1): Mix 80 parts by weight of iso-iso ...

[0167] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0168] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0169] Example 7

[0170] Step (1): Mix 60 parts by weight of iso-iso ...

[0171] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0172] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0173] Example 8

[0174] Step (1): Mix 60 parts by weight of isosorbide-based polycarbonate, 8 parts by weight of styrene-acrylonitrile copolymer, 15 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 8 parts by weight of No. 1 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 5 parts by weight of scratch resistant agent to obtain a premix.

[0175] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0176] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0177] Example 9

[0178] Step (1): Mix 30 parts by weight of iso-adipoyl alcohol-type aliphatic polycarbonate, 30 parts by weight of aliphatic polycarbonate (sorbitol type), 8 parts by weight of styrene-acrylonitrile copolymer, 15 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 8 parts by weight of No. 1 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 5 parts by weight of scratch resistant agent to obtain a premix.

[0179] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0180] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0181] Example 10

[0182] The alloy material was prepared according to the method in Example 1, except that the twin-screw extruder process conditions were as follows: screw length-to-diameter ratio of 36:1; temperature of zone 1 (feeding zone) 160°C; temperature of zone 2 (pressure building zone) 220°C; temperature of zone 3 (pressure building zone) 220°C; temperature of zone 4 (melting zone) 220°C; temperature of zone 5 (exhaust zone) 220°C; temperature of zone 6 (conveyor pressure building zone) 220°C; temperature of zone 7 (devouring zone) 220°C; temperature of zone 9 (pressure building zone) 210°C; die temperature 210°C; die head temperature 200°C; and negative pressure condition of -0.08 MPa. The resulting alloy material was obtained.

[0183] Example 11

[0184] Step (1): Mix 60 parts by weight of isosorbide-based aliphatic polycarbonate, 8 parts by weight of styrene-acrylonitrile copolymer, 15 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 8 parts by weight of No. 2 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 5 parts by weight of scratch resistant agent to obtain a premix.

[0185] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0186] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0187] Example 12

[0188] Step (1): Mix 64 parts by weight of iso-iso-aliphatic polycarbonate, 8 parts by weight of styrene-acrylonitrile copolymer, 15 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 4 parts by weight of No. 1 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 5 parts by weight of scratch resistant agent to obtain a premix.

[0189] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0190] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0191] Example 13

[0192] Step (1): Mix 64 parts by weight of isosorbide-based polycarbonate, 8 parts by weight of styrene-acrylonitrile copolymer, 18 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 8 parts by weight of No. 1 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 2 parts by weight of scratch resistant agent to obtain a premix.

[0193] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0194] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0195] Example 14

[0196] The alloy material was prepared according to the method of Example 2, except that the amount of polymethyl methacrylate was 17 parts by weight and the amount of scratch-resistant agent was 3 parts by weight. The alloy material was obtained.

[0197] Example 15

[0198] The alloy material was prepared according to the method of Example 2, except that the amount of styrene-acrylonitrile copolymer used was 9 parts by weight and the amount of compatibilizer was 1 part by weight. The alloy material was obtained.

[0199] Example 16

[0200] The alloy material was prepared according to the method in Example 2, except that toughening agent #1 was not added. The resulting alloy material was then obtained.

[0201] Example 17

[0202] The alloy material was prepared according to the method of Example 2, except that no scratch-resistant agent was added. The resulting alloy material was obtained.

[0203] Comparative Example 1

[0204] Step (1): Mix 30 parts by weight of iso-iso ...

[0205] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0206] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0207] Comparative Example 2

[0208] Step (1): Mix 30 parts by weight of isosorbide-based aliphatic polycarbonate, 30 parts by weight of PC, 8 parts by weight of styrene-acrylonitrile copolymer, 15 parts by weight of polymethyl methacrylate, 0.4 parts by weight of antioxidant, 0.2 parts by weight of release agent, 2 parts by weight of compatibilizer, 8 parts by weight of No. 1 toughening agent, 2 parts by weight of styrene-acrylonitrile copolymer carrier black masterbatch and 5 parts by weight of scratch resistant agent to obtain a premix.

[0209] Step (2): The obtained premixed material is transported to the loss-in-weight weighing hopper, and then fed into the twin-screw extruder hopper using the loss-in-weight weighing hopper. In the twin-screw extruder, the material is melted, plasticized, sheared, dispersed, extruded, traction, cooled, granulated, and homogenized to obtain the alloy material.

[0210] The twin-screw extruder process conditions are as follows: screw length-to-diameter ratio 40:1; zone 1 feed temperature 160℃; zone 2 pressure build-up temperature 220℃; zone 3 pressure build-up temperature 220℃; zone 4 melt temperature 220℃; zone 5 exhaust temperature 220℃; zone 6 conveying temperature 220℃; zone 7 conveying temperature 220℃; zone 8 pressure build-up temperature 210℃; zone 9 devolatilization temperature 220℃; zone 10 pressure build-up temperature 210℃; die temperature 210℃; and die head temperature 200℃. The vacuum negative pressure is -0.08MPa.

[0211] Comparative Example 3

[0212] The alloy material was prepared according to the method in Example 2, except that iso-idole polycarbonate was replaced with PC in equal amounts. The resulting alloy material was then obtained.

[0213] Comparative Example 4

[0214] The alloy material was prepared according to the method of Example 2, except that no compatibilizer was added. The alloy material was obtained.

[0215] Comparative Example 5

[0216] The alloy material was prepared according to the method of Example 2, except that the styrene-acrylonitrile copolymer was not added. The alloy material was obtained.

[0217] Test case

[0218] The alloy materials prepared in Examples 1-17 and Comparative Examples 1-5 were dried in a forced-air oven at 80°C for 4 hours, and then injection molded into standard samples using an injection molding machine at an injection temperature of 240°C. The samples were then placed under standard conditions of 50% relative humidity and 23°C for 24 hours before performance testing.

[0219] The performance test includes the following tests, and the test results are shown in Table 1.

[0220] (1) Flowability test: The test was conducted in accordance with ISO 1133 "Determination of melt mass flow rate and melt volume flow rate of thermoplastics", and the test conditions were 220℃ / 5kg·10min.

[0221] (2) IZOD notched impact strength test: The test was conducted in accordance with ISO 179 "Determination of impact strength of simply supported plastic beams". The length of the test strip was 80 mm, the width was 10 mm, and the thickness was 4 mm. The kinetic energy condition of the test pendulum was 5.5 J.

[0222] (3) Bending performance test: The test shall be conducted in accordance with ISO 178 "Plastics - Test for bending performance". The length of the sample is 80 mm, the width is 10 mm, the thickness is 4 mm, and the test rate is 2 mm / min.

[0223] (4) Heat distortion temperature test: The test shall be conducted in accordance with ISO 75-1 "Determination of the temperature of deformation under load of plastics". The length of the sample is 80 mm, the width is 10 mm, the thickness is 4 mm, and the test load condition is 1.8 MPa.

[0224] (5) Pencil hardness test: The test shall be conducted in accordance with ISO 15184 "Paints and varnishes - Pencil test for determination of hardness of paint film". The length of the sample is 100 mm and the width is 50 mm. The test rate is 1 mm / s.

[0225] (6) Color of the test color plate: The color difference is measured by a colorimeter, and the L value is calculated according to the relevant provisions of GB / T3979-2008 "Methods for measuring the color of objects". The length of the sample is 100mm and the width is 50mm.

[0226] Table 1

[0227]

[0228]

[0229] As shown in Table 1, the alloy materials prepared using the technical solutions of the present invention in Examples 1-17 have better surface hardness and lower color L value, while also ensuring good mechanical properties; the alloy materials prepared using the most preferred embodiments of the present invention in Examples 2-5 have a surface hardness of up to 3H and a color L value as low as 25.9.

[0230] In this invention, compared with Example 13, where the ratio of polymethyl methacrylate to scratch-resistant agent is 9:1, and Example 14, where the ratio is 17:3, the alloy material prepared by Example 2, which uses the optimal ratio of polymethyl methacrylate to scratch-resistant agent of 2.5:1, can achieve a hardness value of 3H and a colorimetric L value of 25.9, thus obtaining superior surface hardness and high black gloss performance.

[0231] Compared to Example 15, where the ratio of styrene-acrylonitrile copolymer to compatibilizer was 9:1, the alloy material prepared by Example 2 with the optimal ratio of styrene-acrylonitrile copolymer to compatibilizer of 4:1 achieved superior surface hardness and high black gloss properties.

[0232] Compared to Example 8, which uses isosorbide-type polycarbonate, and Example 9, which uses a mixture of aliphatic polycarbonate (isosorbide-type) and isosorbide-type polycarbonate, the alloy material prepared by Example 1 of the present invention using the most preferred isosorbide-type polycarbonate has achieved superior surface hardness and high black gloss performance.

[0233] Compared to Example 11 which uses toughening agent #2, Example 1 of the present invention uses the preferred toughening agent #1 with smaller particle size to prepare alloy materials, and the resulting alloy materials have better surface hardness and high black gloss performance.

[0234] Compared to Example 12, which uses an iso-idyl alcohol-type polycarbonate and toughening agent ratio of 16:1, Example 1 of the present invention uses the most preferred iso-idyl alcohol-type polycarbonate and toughening agent ratio of 7.5:1 to prepare the alloy material, and the resulting alloy material has superior surface hardness and high black gloss performance.

[0235] Compared to Example 16 without the addition of toughening agent #1, the alloy material prepared by adding toughening agent #1 in Example 2 of the present invention has superior surface hardness and high black gloss performance.

[0236] Compared to Example 17, which did not contain a scratch-resistant agent, the alloy material prepared by adding a scratch-resistant agent in Example 2 of the present invention has superior surface hardness and high black gloss performance.

[0237] Compared to Comparative Examples 1 and 2, which use a mixture of PC and aliphatic polycarbonate, and Comparative Example 3, which uses PC alone, the alloy material prepared by Example 1 of the present invention using the most preferred iso-idyl alcohol-type polycarbonate achieved superior surface hardness and high black gloss performance.

[0238] Compared with Comparative Example 4 (without compatibilizer) and Comparative Example 5 (without styrene-acrylonitrile copolymer), the alloy material prepared by adding compatibilizer and styrene-acrylonitrile copolymer in Example 2 of the present invention has superior surface hardness and high black gloss performance.

[0239] It should be noted that the embodiments described above are only for explaining the present invention and do not constitute any limitation on the present invention. The present invention has been described with reference to typical embodiments, but it should be understood that the words used therein are descriptive and explanatory terms, not limiting terms. Modifications can be made to the present invention within the scope of the claims, and revisions can be made to the present invention without departing from the scope and spirit of the present invention. Although the present invention described herein relates to specific methods, materials, and embodiments, it does not mean that the present invention is limited to the specific examples disclosed herein; on the contrary, the present invention can be extended to all other methods and applications with the same function.

Claims

1. An alloy material, characterized in that, The alloy material is obtained by melt extrusion of raw materials comprising 50-80 parts by weight of aliphatic polycarbonate, 5-20 parts by weight of styrene-acrylonitrile copolymer, 8-40 parts by weight of polymethyl methacrylate and 1-5 parts by weight of compatibilizer.

2. The alloy material according to claim 1, characterized in that, The raw materials for the alloy material include 55-65 parts by weight of aliphatic polycarbonate; And / or, the raw materials of the alloy material include 6-10 parts by weight of styrene-acrylonitrile copolymer; And / or, the raw material of the alloy material includes 10-12 parts by weight of polymethyl methacrylate; And / or, the raw materials of the alloy material include 2-4 parts by weight of a compatibilizer; And / or, the raw materials of the alloy material further include 0.1-0.6 parts by weight of antioxidant, preferably 0.3-0.5 parts by weight of antioxidant; And / or, the raw materials of the alloy material further include 0.1-0.5 parts by weight of a release agent, preferably 0.1-0.3 parts by weight of a release agent; And / or, the raw materials of the alloy material further include 1-10 parts by weight of toughening agent, preferably 6-10 parts by weight of toughening agent; And / or, the raw materials of the alloy material further include 1-4 parts by weight of black masterbatch, preferably 1-3 parts by weight of black masterbatch; And / or, the raw materials of the alloy material further include 0.5-12 parts by weight of scratch-resistant agent, preferably 5-10 parts by weight.

3. The alloy material according to claim 2, characterized in that, The total amount of the polymethyl methacrylate and the scratch-resistant agent is 15-25 parts by weight, preferably 18-22 parts by weight; And / or, the weight ratio of the polymethyl methacrylate to the scratch-resistant agent is 0.5-4:1, preferably 1-3:1; And / or, the weight ratio of the aliphatic polycarbonate to the toughening agent is 5-10:1, preferably 7-8:1; And / or, the weight ratio of the styrene-acrylonitrile copolymer to the compatibilizer is 1-5:1, preferably 3-5:

1.

4. The alloy material according to any one of claims 1-3, characterized in that, The aliphatic polycarbonate has a melt index of 8-18 g / 10 min at 230°C and a load of 2.16 kg. And / or, the weight-average molecular weight of the aliphatic polycarbonate is 20,000-40,000 g / mol; And / or, the aliphatic polycarbonate is selected from at least one of sorbitol polycarbonate, isosorbitol polycarbonate, citric acid alcohol polycarbonate and iso-idole alcohol polycarbonate; And / or, the polymethyl methacrylate has a melt index of 2-20 g / 10 min at 230°C and 3.8 kg load; And / or, the weight-average molecular weight of the polymethyl methacrylate is 60,000-400,000 g / mol; And / or, the melt index of the styrene-acrylonitrile copolymer at 220°C and 10 kg load is 15-45 g / 10 min; And / or, the weight-average molecular weight of the styrene-acrylonitrile copolymer is 100,000-250,000 g / mol; And / or, the weight ratio of styrene units to acrylonitrile units in the styrene-acrylonitrile copolymer is 1:1-6, preferably 1:1.5-3.

5. The alloy material according to any one of claims 2-4, characterized in that, The toughening agent is a core-shell copolymer, preferably a core-shell acrylate copolymer; Preferably, the core-shell type acrylate copolymer has a particle size of 1-10 μm, more preferably 1-2 μm; Preferably, the core of the core-shell acrylate copolymer is selected from at least one of butadiene rubber, acrylate rubber, and silicone rubber; Preferably, the shell of the core-shell acrylate copolymer is a polymer of methyl methacrylate and optionally styrene, or polymethyl methacrylate; And / or, the weight ratio of the core to the shell of the core-shell acrylate copolymer is 1-9:1, preferably 1.5-4:1; And / or, the compatibilizer is a maleic anhydride copolymer; Preferably, the weight-average molecular weight of the maleic anhydride copolymer is 5500-200000 g / mol; Preferably, the maleic anhydride copolymer is selected from at least one of styrene-maleic anhydride copolymer, styrene-acrylonitrile-maleic anhydride copolymer, and methyl methacrylate-maleic anhydride copolymer; Preferably, the content of polymeric units formed by maleic anhydride in the maleic anhydride copolymer is 0.5-20 wt%.

6. The alloy material according to any one of claims 2-5, characterized in that, The scratch-resistant agent is a copolymer of methacrylates; Preferably, the scratch-resistant agent is selected from at least one of methyl methacrylate-ethyl methacrylate copolymer, methyl methacrylate-butyl methacrylate copolymer, and ethyl methacrylate-butyl methacrylate. And / or, the weight-average molecular weight of the scratch-resistant agent is 20,000-50,000 g / mol; And / or, the carbon black content of the black masterbatch is 50-60 wt%; And / or, the carbon black particle size in the black masterbatch is 10-50 nm, preferably 20-30 nm; And / or, the black masterbatch is a styrene-acrylonitrile copolymer carrier black masterbatch; And / or, the antioxidant is selected from hindered phenolic antioxidants and / or phosphite antioxidants; Preferably, the hindered phenolic antioxidant is selected from at least one of pentaerythritol ester [β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], octadecyl ester of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, bis(3,5-di-tert-butyl-4-hydroxyphenylpropionyl)hydrazine, and 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene; And / or, the phosphite-type antioxidant is selected from at least one of tris[2,4-di-tert-butylphenyl] phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, and bis(2,6-di-tert-butyl-4-methylbenzyl) pentaerythritol diphosphite; And / or, the release agent is selected from at least one of stearamide, hydrocarbon and fatty acid release agents; Preferably, the fatty acid release agent is selected from at least one of butyl stearate, calcium stearate, methyl stearate, and pentaerythritol tetrastearate.

7. The alloy material according to any one of claims 2-6, characterized in that, The notched impact strength of the alloy material is 30-56 kJ / m. 2 ; And / or, the heat distortion temperature of the alloy material is 88-96℃; And / or, the flexural modulus of the alloy material is 2550-3000 MPa.

8. The method for preparing the alloy material according to any one of claims 1-7, characterized in that, The preparation method includes: Step (1): Mix the raw materials of the alloy material evenly to obtain a premix; Step (2): Add the obtained premix to a twin-screw extruder for melt extrusion to obtain the alloy material.

9. The preparation method according to claim 8, characterized in that, The twin-screw extruder has a screw length-to-diameter ratio of 32-40:1 and a screw temperature of 170-270℃. And / or, in step (2), melt extrusion is performed under conditions of -0.075 MPa to -0.08 MPa; Preferably, the screw temperature includes: zone 1 feeding zone temperature of 150-170℃, zone 2 pressure building zone temperature of 210-250℃, zone 3 pressure building zone temperature of 210-250℃, zone 4 melting temperature of 210-250℃, zone 5 exhaust temperature of 210-250℃, zone 6 conveying temperature of 210-250℃, zone 7 conveying temperature of 210-250℃, zone 8 pressure building temperature of 200-240℃, zone 9 devolatilization zone temperature of 210-250℃, zone 10 pressure building zone temperature of 200-240℃, die temperature of 200-240℃, and die head temperature of 190-230℃.

10. A car trim component, characterized in that, The automotive trim includes components formed from the alloy material of any one of claims 1-7 or the alloy material prepared by the preparation method of claim 8 or 9; Preferably, the automotive trim includes automotive interior trim and automotive exterior trim.

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