Overmolded plastic articles, their uses and methods of manufacture

Abstract

The present invention relates to a metal-plastic assembly comprising at least one metal insert, said metal insert being overmolded with at least one polymer composition comprising at least one of polyamide and polyarylene sulfide and flat glass fiber, which provides long-term thermal stability and low loss of mechanical properties over long time and temperature cycles, and is particularly advantageous for use in automotive applications, such as bus bars in e-mobility / power electronics applications.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 386941, filed December 12, 2022, and European Patent Application No. 23156796.7, filed February 15, 2023, the entire contents of each of which are incorporated herein by reference for all purposes.

[0002] The present invention relates to a metal-plastic assembly comprising at least one metal insert, the metal insert being overmolded with at least one polymer composition comprising at least one of a polyamide and a polyarylene sulfide and flat glass fibers. In this regard, the overmolded article of the present invention provides long-term thermal stability and low loss of mechanical properties over extended time and temperature cycling, making it particularly advantageous for use in automotive applications, such as bus bars in e-mobility / power electronics applications.

[0003] Additional advantages and other features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned from the practice of the invention. The advantages of the present invention may be realized and obtained as particularly pointed out in the appended claims. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. The present description is to be regarded as illustrative in nature and not as restrictive. [Background technology]

[0004] Techniques that require assembling an insert (typically metal) with plastic are well known in the art and generally involve melt processing the plastic around a metal insert, encapsulating the insert with plastic to form a single molded plastic piece that is generally stronger than those formed using secondary assembly.

[0005] It is generally recognized that molten plastic surrounding a metal insert contracts as it cools, creating "hoop" stresses in the plastic. This hoop stress results in a constant stress on the plastic part throughout its lifespan and can lead to cracking if not minimized during the manufacturing process. In fact, such residual stresses are generally believed to be the primary cause of reduced environmental stress cracking resistance, poor short- and long-term (creep, fatigue) mechanical behavior, and poor performance during thermal cycling—all of which are exacerbated when the metal part has sharp edges or weld seams.

[0006] Currently, processing and design parameters must be adjusted to minimize these phenomena, while there is a need to provide plastic materials with a better balance of properties for these metal / plastic insert assemblies. Summary of the Invention

[0007] The present invention relates to a metal-plastic assembly comprising: a metal insert having a surface; a plastic component in contact with at least a portion of the surface of the metal insert, (A) at least one polymer selected from the group consisting of polyamide polymers [polymers (PA)] and poly(arylene sulfide) polymers [polymers (PAS)]; (B) Flat glass fiber [fiber (FGF)] a plastic component manufactured from a polymer composition [composition (C)] comprising The present invention relates to a metal-plastic assembly comprising:

[0008] Applicant has surprisingly found that by incorporating flat glass fibers into plastic components, the metal-plastic assembly of the present invention provides long-term thermal stability and low loss of mechanical properties over extended time and temperature cycles, making it particularly advantageous for use in automotive applications. DETAILED DESCRIPTION OF THE INVENTION

[0009] Polymer Composition (C) The polyamide composition (C) described above may comprise a polymer (PA), a polymer (PAS), or a mixture thereof. Nevertheless, to qualify as a polyamide-based or poly(arylene sulfide)-based composition, it is generally understood that the polyamide composition (C) comprises a substantial amount of the polymer (PA) or a substantial amount of the polymer (PAS). A "substantial amount" is intended herein to mean that the designated polymer is the polymer that is predominantly contained in said composition (C), among all other possible polymeric components (if any).

[0010] The polymer (PA) may be present in the polyamide-based composition (C) in a total amount of more than 30 wt.-%, more than 35 wt.-%, more than 40 wt.-%, or more than 45 wt.-%, based on the total weight of the polymer composition (C). The polyamide (PA) may be present in the polymer composition (C) in a total amount of less than 95 wt.-%, in particular less than 90 wt.-%, less than 80 wt.-%, less than 70 wt.-%, or less than 60 wt.-%, based on the total weight of the polymer composition (C).

[0011] The polyamide (PA) may be present in the polyamide composition (C) in an amount ranging from 35 to 60% by weight, for example, from 40 to 55% by weight, based on the total weight of the polyamide composition (C).

[0012] Similarly, the polymer (PAS) may be present in the poly(arylene sulfide)-based composition (C) in a total amount of more than 30 wt%, more than 35 wt%, more than 40 wt%, or more than 45 wt%, based on the total weight of the polymer composition (C). The polymer (PAS) may be present in the poly(arylene sulfide)-based composition (C) in a total amount of less than 95 wt%, in particular less than 90 wt%, less than 80 wt%, less than 70 wt%, or less than 60 wt%, based on the total weight of the polymer composition (C).

[0013] The polymer (PAS) may be present in the poly(arylene sulfide)-based composition (C) in an amount ranging from 35 to 60 wt %, for example, from 40 to 55 wt %, based on the total weight of the polyamide composition (C).

[0014] The polymer composition (C) may also contain one component selected from the group consisting of reinforcing agents other than the flat glass fibers, toughening agents, plasticizers, colorants, pigments, antistatic agents, dyes, lubricants, heat stabilizers, light stabilizers, flame retardants, nucleating agents, crosslinking agents, and antioxidants.

[0015] As mentioned above, the polymer composition (C) of the present invention may contain a toughening agent. The toughening agent generally has a low glass transition temperature (T g ) polymers, such as polymers with a T below room temperature, below 0°C, or even below -25°C g Its low T g As a result, the toughening agent is typically elastomeric at room temperature. The toughening agent may be a functionalized polymer backbone.

[0016] The polymer backbone of the toughening agent may be selected from elastomeric backbones comprising polyethylene and copolymers thereof, such as ethylene-butene, ethylene-octene, polypropylene and copolymers thereof, polybutene, polyisoprene, ethylene-propylene rubber (EPR), ethylene-propylene-diene monomer rubber (EPDM), ethylene-acrylate rubber, butadiene-acrylonitrile rubber, ethylene-acrylic acid (EAA), ethylene-vinyl acetate (EVA), acrylonitrile-butadiene-styrene rubber (ABS), block copolymer styrene ethylene butadiene styrene (SEBS), block copolymer styrene butadiene styrene (SBS), core-shell elastomers of the methacrylate-butadiene-styrene (MBS) type, or mixtures of one or more of the above.

[0017] When the toughening agent is functionalized, the backbone functionalization can result from copolymerization of monomers containing the functionalization or from grafting the polymer backbone with additional components.

[0018] Specific examples of functionalized toughening agents are, inter alia, terpolymers of ethylene, acrylic ester and glycidyl methacrylate, copolymers of ethylene and butyl ester acrylate, copolymers of ethylene, butyl ester acrylate and glycidyl methacrylate, ethylene-maleic anhydride copolymers, EPR grafted with maleic anhydride, styrene-maleimide copolymers grafted with maleic anhydride, SEBS copolymers grafted with maleic anhydride, styrene-acrylonitrile copolymers grafted with maleic anhydride, ABS copolymers grafted with maleic anhydride.

[0019] The toughening agent may be present in polymer composition (C) in a total amount of more than 1 wt%, more than 2 wt%, or more than 3 wt%, based on the total weight of composition (C). The toughening agent may be present in composition (C) in a total amount of less than 30 wt%, less than 20 wt%, less than 15 wt%, or less than 10 wt%, based on the total weight of polymer composition (C).

[0020] Polyamide or Polymer (PA) The polyamide or polymer (PA) of the polymer composition (C) comprises repeating units (R 2 ) derived from the polycondensation of a diamine and a diacid of the following formula (AABB): PA ) and / or units derived from the polycondensation of amino acids or lactams of the following formula (AB): -NR H -R AB -C(O)- (AB) (I) -NR H -R BB -NR H -C(O)-R AA -C(O)- (AABB) (II) (In the formula, R H is hydrogen or a hydrocarbon group, preferably R H is hydrogen, and R AB , R BB , R AA are equal to or different from each other and are divalent hydrocarbon radicals optionally containing one or more heteroatoms. Includes.

[0021] The expression "(co)polyamide" or "polyamide" as used herein refers to the number of moles of repeating units of the (co)polyamide [polyamide (A)], based on the total number of moles of repeating units of the (co)polyamide [polyamide (A)]. - the repeating units (R PA a homopolyamide containing substantially 100 mol % of at least about 85 mol%, preferably at least about 90 mol%, more preferably at least about 95 mol%, such as at least about 96 mol%, at least about 97 mol%, at least about 98 mol%, at least about 99 mol% of repeat units of formula (I) (R PA ) containing copolyamide is used to refer to.

[0022] Specifically, the repeating units (I) and (II) of the polyamide (PA) are a mixture (M1) comprising at least a diacid [acid (DA)] (or a derivative thereof) and at least a diamine [amine (NN)] (or a derivative thereof), a mixture (M2) containing at least a lactam [lactam (L)], a mixture (M3) comprising at least aminocarboxylic acids [amino acids (AN)], and - combinations of these The compound may be a condensation product of a mixture of at least one compound selected from the group consisting of:

[0023] Acid (DA) derivatives include in particular salts, anhydrides, esters and acid halides capable of forming amide groups, while amine (NN) derivatives include in particular their salts equally capable of forming amide groups.

[0024] The acid (DA) can be an aromatic dicarboxylic acid containing two reactive carboxylic acid groups [acid (AR)] or an aliphatic dicarboxylic acid containing two reactive carboxylic acid groups [acid (AL)]. For purposes of this invention, a dicarboxylic acid is considered "aromatic" if the two reactive carboxylic acid groups are attached to one or more aromatic groups.

[0025] Non-limiting examples of acids (AR) include phthalic acids, including isophthalic acid (IA) and terephthalic acid (TA), 2,5-pyridinedicarboxylic acid, 2,4-pyridinedicarboxylic acid, 3,5-pyridinedicarboxylic acid, 2,2-bis(4-carboxyphenyl)propane, bis(4-carboxyphenyl)methane, 2,2-bis(4-carboxyphenyl)hexafluoropropane, 2,2-bis(4-carboxyphenyl)ketone, 4,4'-bis(4-carboxyphenyl)sulfone, 2,2-bis(3- bis(3-carboxyphenyl)propane, bis(3-carboxyphenyl)methane, 2,2-bis(3-carboxyphenyl)hexafluoropropane, 2,2-bis(3-carboxyphenyl)ketone, bis(3-carboxyphenoxy)benzene, naphthalenedicarboxylic acids including 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 2,3-naphthalenedicarboxylic acid, and 1,8-naphthalenedicarboxylic acid, and biphenyl-4,4'-dicarboxylic acid. Particularly preferred acids (Ar) are Ia and Ta.

[0026] Among the acids (AL), particularly malonic acid (HOOC-CH2-COOH), succinic acid [HOOC-(CH2)2-COOH], glutaric acid [HOOC-(CH2)3-COOH], 2,2-dimethyl-glutaric acid [HOOC-C(CH3)2-(CH2)2-COOH], adipic acid [HOOC-(CH2)4-COOH], 2,4,4-trimethyl-adipic acid [HOOC-CH(CH3)-CH2-C(CH3)2-CH2-COOH], pimelic acid [HOOC-(CH2 5- COOH], suberic acid [HOOC-(CH2)6-COOH], azelaic acid [HOOC-(CH2)7-COOH], sebacic acid [HOOC-(CH2)8-COOH], undecanedioic acid [HOOC-(CH2)9-COOH], dodecanedioic acid [HOOC-(CH2 10 -COOH], tridecanedioic acid [HOOC-(CH2) 11 -COOH], tetradecanedioic acid [HOOC-(CH2) 12 -COOH], octadecanedioic acid [HOOC-(CH2) 16 -COOH] can be mentioned.

[0027] Furthermore, acids (AL) which may be used include alicyclic radical-containing acids, including in particular 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, optionally as cis or trans diastereoisomers, in mixtures.

[0028] According to a particular embodiment, acids (DA) containing ionizable groups can be used as polycondensation monomers for the polyamide (A) [acids (IDA)], among which mention may be made in particular of phenolic hydroxyl groups, sulfonic acid groups (generally aromatic sulfonic acid groups), phosphonic acid groups, onium groups (including phosphonium and ammonium groups), etc. Non-limiting examples of this type of acid (IDA) that can be used within the framework of the present invention are in particular 4-hydroxyisophthalic acid, 5-hydroxyisophthalic acid, 2-hydroxyterephthalic acid, 2,5-dihydroxyterephthalic acid, 4,6-dihydroxyisophthalic acid, 5-sulfoisophthalic acid (and their salts, such as Li, K, Na, Ag salts) and 2-sulfoterephthalic acid (and their salts, such as Li, K, Na, Ag salts).

[0029] The acid containing an ionizable group (IDA) may be used in combination with the acid (AR) and / or the acid (AL) as detailed above.

[0030] The amine (NN) is usually selected from the group consisting of aliphatic diamines, aromatic diamines and mixtures thereof.

[0031] The aliphatic diamines (NNa) may be or comprise aliphatic alkylenediamines (NNaa) having 2 to 18 carbon atoms, and / or may be or comprise cycloaliphatic diamines, i.e. diamines containing cycloaliphatic groups having 2 to 18 carbon atoms [amines (NNca)].

[0032] The aliphatic alkylenediamines (NNaa) are advantageously 1,2-diaminoethane, 1,2-diaminopropane, propylene-1,3-diamine, 1,3-diaminobutane, 1,4-diaminobutane, 1,5-diaminopentane, 1,5-diamino-2-methylpentane, 1,4-diamino-1,1-dimethylbutane, 1,4-diamino-1-ethylbutane, 1,4-diamino-1,2-dimethylbutane, 1,4-diamino-1,3-dimethylbutane, 1,4-diamino-1,4-diamine, Methylbutane, 1,4-diamino-2,3-dimethylbutane, 1,2-diamino-1-butylethane, 1,6-diaminohexane, 1,7-diaminoheptane, 1,8-diamino-octane, 1,6-diamino-2,5-dimethylhexane, 1,6-diamino-2,4-dimethylhexane, 1,6-diamino-3,3-dimethylhexane, 1,6-diamino-2,2-dimethylhexane, 1,9-diaminononane, 1,6-diamino-2,2,4-trimethylhexane, 1,6-diamino -2,4,4-trimethylhexane, 1,7-diamino-2,3-dimethylheptane, 1,7-diamino-2,4-dimethylheptane, 1,7-diamino-2,5-dimethylheptane, 1,7-diamino-2,2-dimethylheptane, 1,10-diaminodecane, 1,8-diamino-1,3-dimethyloctane, 1,8-diamino-1,4-dimethyloctane, 1,8-diamino-2,4-dimethyloctane, 1,8-diamino-3,4-dimethyloctane, 1,8-diamino-4,5- dimethyloctane, 1,8-diamino-2,2-dimethyloctane, 1,8-diamino-3,3-dimethyloctane, 1,8-diamino-4,4-dimethyloctane, 1,6-diamino-2,4-diethylhexane, 1,9-diamino-5-methylnonane, 1,11-diaminoundecane, and 1,12-diaminododecane, 1,13-diaminotridecane, 2,5-bis(aminomethyl)tetrahydrofuran, N-methyl-bis-hexamethylene-triamine.

[0033] The aliphatic alkylenediamine (NNaa) preferably comprises at least one diamine selected from the group consisting of linear alkylenediamines selected from 1,6-diaminohexane, 1,8-diaminooctane, 1,10-diaminodecane, 1,12-diaminododecane, and mixtures thereof. More preferably, the linear alkylenediamine comprises at least one diamine selected from the group consisting of 1,6-diaminohexane, 1,10-diaminodecane, and mixtures thereof. Even more preferably, the linear alkylene alkylenediamine is 1,6-diaminohexane.

[0034] According to another embodiment, at least one of the amines (NN) is a cycloaliphatic diamine, i.e. a diamine comprising an cycloaliphatic group [amine (NNca)], which amine (NNca) is typically selected from the group consisting of isophoronediamine, bis(3,5-dialkyl-4-aminocyclohexyl)methane, bis(3,5-dialkyl-4-aminocyclohexyl)ethane, bis(3,5-dialkyl-4-aminocyclohexyl)propane, bis(3,5-dialkyl-4-aminocyclohexyl)butane, bis(3-methyl-4-aminocyclohexyl)methane, p-bis(aminocyclohexyl)methane, isopropylidenedi(cyclohexylamine), 4,4'-diamino-3,3'-dimethyldicyclohexylmethane, 1,3-bis(aminomethyl)cyclohexane and 1,4-bis(aminomethyl)cyclohexane.

[0035] The aromatic diamine (NNar) is preferably selected from the group consisting of meta-phenylenediamine, meta-xylylenediamine and para-xylylenediamine.

[0036] According to certain other embodiments, at least one amine (NN) containing an ether bond can be used as a polycondensation monomer for polyamide (A) [amine (NNE)], and exemplary embodiments of amines (NNE), otherwise referred to as polyetherdiamines, are in particular those of the formula: -(OCH2-CHR J ) n -(In the formula, R Jis H or a C1-C3 alkyl group, preferably -CH3, and n is an integer of 1 to 15), and a moiety of the formula: -(OC(R' J )(R” J )) m -O-(in the formula, R' J and R'' J are equal or different from each other and at each occurrence and are H or a C1-C3 alkyl group, preferably -CH3, and m is an integer from 1 to 15.

[0037] Amino acids (AN) suitable for use in the preparation of polyamide (A) may be selected from the group consisting of 6-aminohexanoic acid, 9-aminononanoic acid, 10-aminodecanoic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, 13-aminotridecanoic acid.

[0038] The addition of one or more polyfunctional acid / amine monomers containing three or more carboxylic acid groups and amine groups, such as polycarboxylic acids containing three or more carboxylic acid groups, polyamines containing three or more amine groups, polyfunctional diacids containing two carboxylic acid groups and one or more amine groups, and polyfunctional diamines containing two amine groups and one or more carboxylic acid groups, to any of the mixtures (M1), (M2), (M3) and combinations thereof, remains within the scope of the present invention. The incorporation of said polyfunctional acid / amine monomers generally results in star-shaped or dendritic branched structures, such as those described in particular in WO 97 / 24388 (NYLTECH ITALIA) July 10, 1997 and WO 99 / 64496 (NYLTECH ITALIA) June 12, 1999.

[0039] It is further understood that one or more end-capping agents [agent (M)] can be added to any of the mixtures (M1), (M2), (M3) and combinations thereof for the preparation of polyamide (A) without departing from the scope of the present invention. Agent (M) is generally selected from the group consisting of acids containing only one reactive carboxylic acid group [acid (MA)] and amines containing only one reactive amine group [agent (MN)].

[0040] The acid (MA) is preferably selected from the group consisting of acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, caprylic acid, lauric acid, stearic acid, cyclohexanecarboxylic acid, benzoic acid, 3-sulfobenzoic acid (and salts thereof, such as Li, K, Na, Ag salts), 4-sulfobenzoic acid (and salts thereof, such as Li, K, Na, Ag salts), preferably acetic acid and benzoic acid.

[0041] The amine (MN) is preferably selected from the group consisting of methylamine, ethylamine, butylamine, hexylamine, octylamine, benzylamine, aniline, toluidine.

[0042] Preferred polyamides (PA) are: (A1) Semi-aromatic polyamide, preferably - at least the above-mentioned aromatic diacids (AR) (and derivatives thereof), optionally in combination with the above-mentioned aliphatic diacids (AL) (and derivatives thereof), and - at least the aliphatic diamines [amines (NNa)] (and derivatives thereof) described above, which may be aliphatic alkylenediamines or cycloaliphatic diamines as described above; and (A3) Semi-aromatic polyamide, preferably - at least one aliphatic diacid (AL) as defined above (and its derivatives), and - at least one aromatic diamine (and its derivatives) 1. A semi-aromatic polyamide comprising, preferably consisting of, repeating units which are the condensation product of a mixture comprising:

[0043] Typical polyamides (PA) of type (A1) are: polyamides comprising, preferably consisting of, units which are condensation products of a mixture of 1,6-diaminohexane and terephthalic acid, optionally in combination with isophthalic acid, i.e. the polycondensation products obtained are polyamide 6T or polyamide 6T / 6I, - polyamides comprising, preferably consisting of, units which are condensation products of a mixture of 1,6-diaminohexane, 1,10-decamethylenediamine and optionally 1,3-bis-(aminomethyl)-cyclohexane and terephthalic acid, i.e. the polycondensation products obtained are polyamide 6T / 10T or polyamide 6T / 10T / BACT, polyamides comprising, preferably consisting of, units which are condensation products of a mixture of 1,6-diaminohexane, adipic acid and terephthalic acid, optionally in combination with isophthalic acid, i.e. the polycondensation products obtained are polyamide 6T / 66 or polyamide 6T / 6I / 66, - polyamides comprising, preferably consisting of, units which are the condensation product of 1,6-diaminohexane with a mixture of 1,3-bis-(aminomethyl)-cyclohexane (BAC), 1,4-cyclohexanedicarboxylic acid (cis, trans or cis / trans mixtures) (CHDA) and terephthalic acid, i.e. the polycondensation product obtained is polyamide 6T / BACT / 6CHDA / BACCHDA. is.

[0044] Representative polyamides of type (A2) are: - a polyamide comprising, preferably consisting of, units which are the condensation product of a mixture of m-xylenediamine (MXDA) and adipic acid, i.e. the polycondensation product obtained is polyamide MXD6. is.

[0045] Poly(arylene sulfide) polymer or polymer (PAS) Poly(arylene sulfide) (“PAS”) polymers have the following formula: [-Ar1-S-] (R PAS1 ) (In the formula, -Ar1- is [ka] and wherein: R is, in each case, C1 to C 12 Alkyl groups, C7-C 24 Alkylaryl group, C7-C 24 Aralkyl groups, C6-C 24 Arylene groups and C6-C 18 aryloxy groups; T is selected from the group consisting of a bond, —CO—, —SO—, —O—, —C(CH)—, —C(CF)—, phenyl, and —CH—; i, in each occurrence, is an independently selected integer from 0 to 4; j, in each occurrence, is an independently selected integer from 0 to 3. It contains a repeating unit (RPAS1) represented by:

[0046] In formulas (a), (b), and (c), when i or j is zero, the corresponding benzyl ring is unsubstituted. Similar notation is used throughout this specification. Furthermore, each formula (a) to (c) contains two dashed bonds, one of which is a bond between the repeating unit (R PAS1 ) to the distinct sulfur atom, and the other bond is PAS1 ) to an atom outside the repeat unit (e.g., to an adjacent repeat unit). Similar notation is used throughout.

[0047] Preferably, -Ar1- is represented by either formula (a) or (b), more preferably by formula (a).

[0048] More preferably, -Ar1- is of the following formula: [ka] is expressed by

[0049] Even more preferably, -Ar1- is represented by any of formulas (a-1), (a-2) and (a-3) (wherein i is zero).

[0050] A unit (R PAS1 ) when -Ar1- is present together with units of either formula (a-2) and / or (a-3), in the polymer (PAS) -Ar1- is a repeating unit (R PAS1 The total concentration of -Ar1- is a unit (R PAS1 ), at most 10 mol %, at most 5 mol %, at most 3 mol %, at most 1 mol % based on the total amount of

[0051] The unit (R PAS1 ), i.e., having the formula: [ka] Units of R PAS1 Polymers having the structure (PAS) are called poly(phenylene sulfide) (PPS) polymers.

[0052] The polymer (PPS) has the formula: [ka] and the polymer (PPS) may additionally contain any unit of the unit (R PPS-m ) and / or (R PPS-o ), the repeating unit (R PPS-m ) and / or (R PPS-o The total concentration of ) is expressed in units (R PPS ), (R PPS-m ) and (R PPS-o ), is understood to be at most 10 mol %, at most 5 mol %, at most 3 mol %, at most 1 mol %, based on the total amount of

[0053] In some embodiments, the repeating units (R PAS1 ) is at least 50 mol%, at least 60 mol%, at least 70 mol%, at least 80 mol%, at least 90 mol%, at least 95 mol%, at least 98 mol%, at least 99 mol%, or at least 99.9 mol%.

[0054] In some embodiments, the polymer (PAS) comprises a repeating unit (R PAS1 ) and a different repeating unit (R PAS2 ), and the repeating unit (R PAS2 ) is expressed as: [-Ar2-S-] (R PAS2 ) (In the formula, -Ar2- is a group represented by the following formula: [ka] (Wherein, R1 is C1 to C 10 A straight-chain or branched alkyl group, preferably, R1 is -CH3. (represented by is expressed by

[0055] In formula (d), the dashed bond with an "*" indicates a repeat unit (R PAS2 ) to the sulfur atom, and the dashed bond without "*" indicates the repeat unit (R PAS2 ) to atoms outside the unit (R PAS2 ), the R1 substituent is ortho to the -S- moiety.

[0056] It will be appreciated that in some embodiments, the polymers (PAS) are different from each other and have repeating units (R PAS1 ) and (R PAS2 ) may have additional repeat units different from

[0057] In some embodiments, the repeating units (RPAS1 ) and (R PAS2 ) is at least 50 mol%, at least 60 mol%, at least 70 mol%, at least 80 mol%, at least 90 mol%, at least 95 mol%, at least 98 mol%, at least 99 mol%, or at least 99.9 mol%.

[0058] As used herein, the molar concentration of a repeat unit in a polymer is relative to the total number of repeat units in that polymer, unless expressly specified otherwise.

[0059] In some embodiments, the repeating units (R PAS1 ) is at least 50 mol%, at least 60 mol%, at least 70 mol%, at least 80 mol%, at least 85 mol%, at least 88 mol%, at least 90 mol%, at least 95 mol%, at least 97 mol%, at least 98 mol%, at least 98.5 mol%, or at least 99 mol%.

[0060] In some embodiments, the repeating units (R PAS2 ) may be at least 0.5 mol %, at least 1 mol %, at least 1.5 mol %, at least 2 mol %, or at least 2.5 mol %. In some embodiments, the concentration of repeating units (R PAS2 ) is 15 mol % or less, 12 mol % or less, 10 mol % or less, or 8 mol % or less.

[0061] In some embodiments, the repeating units (R PAS2 ) may be 0.5 mol % to 15 mol %, 0.5 mol % to 12 mol %, 0.5 mol % to 10 mol %, 0.5 mol % to 8 mol %, 1 mol % to 15 mol %, 1 mol % to 12 mol %, 1 mol % to 10 mol %, 1 mol % to 8 mol %, 2 mol % to 8 mol %, or 2.5 mol % to 8 mol %.

[0062] In some embodiments, the repeating units (R PAS1) and (R PAS2 The number of repeating units (R PAS2 ) may be at least 1 mol %, at least 1.5 mol %, at least 2 mol %, or at least 2.5 mol %.

[0063] In some embodiments, the repeating unit (R PAS1 ) and (R PAS2 The number of repeating units (R PAS2 ) is 15 mol % or less, 12 mol % or less, 10 mol % or less, or 8 mol % or less.

[0064] The polymer (PAS) is PAS2 ), but the polymer (PAS) may contain units (R PAS2 According to these embodiments, the repeating units (R PAS1 ) is at least 50 mol%, at least 60 mol%, at least 70 mol%, at least 80 mol%, at least 90 mol%, at least 95 mol%, at least 98 mol%, at least 99 mol%, or at least 99.9 mol%.

[0065] Most preferably, the polymer (PAS) comprises repeating units (R PAS1 The term "consisting essentially of," when used to characterize the constituent parts of a polymer (PAS), is intended to indicate that small amounts of spurious units (e.g., less than 0.1 mol %), impurities, or chain ends may be present without altering the advantageous properties of the polymer (PAS).

[0066] Most preferably, the polymer (PAS) is a polymer (PPS) as described above and has the formula (R PPS ) units (R PAS1 A polymer consisting essentially of (PPS) is most preferred.

[0067] The polymer (PAS) may have a melt flow rate (at 315.6°C under a load of 1.27 kg according to ASTM D1238, Procedure B) of at most 700 g / 10 min, more preferably at most 500 g / 10 min, even more preferably at most 200 g / 10 min, even more preferably at most 50 g / 10 min, and even more preferably at most 35 g / 10 min.

[0068] Preferably, the polymer (PAS) has a melt flow rate (at 315.6°C under a load of 1.27 kg according to ASTM D1238, Procedure B) of at least 1 g / 10 min, more preferably at least 5 g / 10 min, even more preferably at least 10 g / 10 min, and even more preferably at least 15 g / 10 min.

[0069] The polymer (PAS) can be amorphous or semi-crystalline. As used herein, an amorphous polymer has an enthalpy of fusion ("ΔH") of 5 Joules / g ("J / g") or less. f Those skilled in the art will appreciate that if a polymer (PAS) is amorphous, it will have a detectable melting temperature (T m ) is not present. Therefore, those skilled in the art will recognize that the polymer (PAS) does not have T m It will be appreciated that when the polymer (PAS) has a ΔH of at least 10 J / g, at least 20 J / g, at least or at least 25 J / g, it refers to a semi-crystalline polymer. Preferably, the polymer (PAS) is semi-crystalline. In some embodiments, the polymer (PAS) has a ΔH of at least 10 J / g, at least 20 J / g, at least or at least 25 J / g. f In some embodiments, the polymer (PAS) has a ΔH of 90 J / g or less, 70 J / g or less, or 60 J / g or less. f In some embodiments, the polymer (PAS) has a ΔH of 10 J / g to 90 J / g or 20 J / g to 70 J / g. f ΔH f can be measured by differential scanning calorimetry (DSC) according to ASTM D3418.

[0070] Preferably, the polymer (PAS) has a melting point of at least 240°C, more preferably at least 248°C, and even more preferably at least 250°C, as determined by differential scanning calorimetry (DSC) according to ASTM D3418.

[0071] Preferably, the polymer (PAS) has a melting point of at most 320°C, more preferably at most 300°C, and even more preferably at most 295°C, as determined by differential scanning calorimetry (DSC) according to ASTM D3418.

[0072] Preferably, the polymer (PAS) has a weight average molecular weight (Mw) as measured by gel permeation chromatography of at least 40,000 g / mol, preferably 45,000 g / mol, more preferably at least 50,000 g / mol, and even more preferably at least 55,000 g / mol.

[0073] Preferably, the polymer (PAS) has a weight average molecular weight (Mw) as measured by gel permeation chromatography of at most 120,000 g / mol, more preferably at most 110,000 g / mol, even more preferably at most 100,000 g / mol, and even more preferably at most 90,000 g / mol.

[0074] Preferably, the polymer (PAS) has as its primary technical characteristic a calcium content of less than 200 ppm as measured by X-ray fluorescence (XRF) analysis calibrated with standards of known calcium content as measured by inductively coupled plasma-solid state optical emission spectroscopy (ICP-OES) in accordance with ASTM UOP714-07.

[0075] An exemplary polymer (PAS) is commercially available as RYTON® PPS from Solvay Specialty Polymers USA, LLC.

[0076] The polymer (PAS) may advantageously comprise at least one functional group at at least one of its chain ends. According to some embodiments, the polymer (PAS) has a functional group at each end of its chain. As used herein, the term "chain" is intended to mean the longest series of covalently bonded atoms that together create a continuous chain in the molecule.

[0077] If present, preferably the functional group of the polymer (PAS) is of the following formula (I): [ka] wherein Z is selected from the group consisting of halogen atoms (e.g., chlorine), carboxyl groups, amino groups, hydroxyl groups, thiol groups, acid anhydride groups, isocyanate groups, amide groups, and derivatives thereof, such as sodium, lithium, potassium, calcium, magnesium, and zinc salts. Follow.

[0078] If present, the functional groups are preferably reactive towards the polymer (POS) and are selected from the group consisting of carboxyl groups, amino groups, hydroxyl groups, thiol groups, acid anhydride groups, isocyanate groups, amide groups and derivatives thereof, such as sodium, lithium, potassium, calcium, magnesium, zinc salts.

[0079] Preferably, the functional group is selected from the group consisting of a hydroxyl group, a thiol group, a hydroxylate and a thiolate.

[0080] Preferably, the polymer (PAS) is linear.

[0081] When functional groups are present, preferably the polymer (PAS) is linear and contains at least one reactive functional group at at least one chain end. In one embodiment, the polymer (PAS) is linear and contains at least one reactive functional group at each end of its chain.

[0082] Flat glass fiber The polymer composition (C) further contains flat glass fibers.

[0083] In the present invention, the expression "flat glass fiber" is intended to refer to glass fibers having a non-circular cross section. Flat glass fibers suitable for use as reinforcing fillers in the compositions of the present invention can have any non-circular cross section, such as an elliptical cross section, an oval cross section, a rectangular cross section, a cross section in which a semicircle is connected to both short sides of a rectangle, and a cocoon-shaped cross section.

[0084] The aspect ratio of the non-circular cross section of the flat glass fiber is advantageously 1.0 to 10, preferably 1.5 to 7.0, more preferably 2.0 to 6.0, and most preferably 3.0 to 5.0.

[0085] The aspect ratio according to this specification can be determined by observing the cross section of a flattened glass fiber with a scanning electron microscope (SEM) and analyzing the image obtained by circumscribing the non-circular cross section of the flattened glass fiber with an imaginary rectangle that corresponds to the longest and shortest dimensions of the cross section. The aspect ratio is obtained by calculating A (= length Ra) / B (= length Rb), where A and B are the lengths of the long side Ra and the short side Rb of the rectangle that circumscribing the flattened glass fiber in the observed image. The aspect ratio is determined by measuring the individual shortest and longest dimensions of at least 10 different images of the cross section of the flattened glass fiber and averaging multiple such measurements.

[0086] Glass fibers are silica-based glass compounds containing several metal oxides that can be tailored to produce various types of glass. The primary oxide is silica in the form of silica sand, while other oxides, such as calcium, sodium, and aluminum, are incorporated to lower the melting temperature and prevent crystallization. Glass fibers can be added as endless fibers or chopped glass fibers. All glass fiber types, including A, C, D, E, M, S, R, and T-glass fibers (as described in Chapter 5.2.3, pages 43-48 of Additives for Plastics Handbook, 2nd ed., John Murphy), or any mixture thereof, can be used. For example, E-glass fibers typically have an elastic modulus of at least 68, preferably at least 70, and more preferably at least 72 GPa, as measured according to ASTM D2343. R-, S-, and T-glass fibers are high-modulus glass fibers, typically having an elastic modulus of at least 76, preferably at least 78, more preferably at least 80, and most preferably at least 82 GPa, as measured according to ASTM D2343.

[0087] E-, R-, S-, and T-glass fibers are well known in the art. They are described, inter alia, in Fiberglass and Glass Technology, Wallenberger, Frederick T.; Bingham, Paul A. (Eds.), 2010, XIV, chapter 5, pages 197-225. R-, S-, and T-glass fibers consist essentially of oxides of silicon, aluminum, and magnesium. In particular, they typically contain 62-75 wt. % SiO2, 16-28 wt. % Al2O3, and 5-14 wt. % MgO. In contrast to the common E-glass fibers widely used in polymer compositions, R-, S-, and T-glass fibers contain less than 10 wt. % CaO.

[0088] In some embodiments, the flat glass fibers are chopped fibers having an average length of 3 mm to 50 mm. In some such embodiments, the glass fibers have an average length of 3 mm to 10 mm, 3 mm to 8 mm, 3 mm to 6 mm, or 3 mm to 5 mm. In alternative embodiments, the glass fibers have an average length of 10 mm to 50 mm, 10 mm to 45 mm, 10 mm to 35 mm, 10 mm to 30 mm, 10 mm to 25 mm, or 15 mm to 25 mm. The average length of the glass fibers may be considered as the average length of the glass fibers before incorporation into the polymer composition, or may be considered as the average length of the glass fibers in the polymer composition.

[0089] In some embodiments, the glass fibers have a cross-sectional longest dimension of at least 15 μm, preferably at least 20 μm, more preferably at least 22 μm, and even more preferably at least 25 μm. Additionally or alternatively, in some embodiments, the glass fibers have a cross-sectional longest dimension of at most 40 μm, preferably at most 35 μm, more preferably at most 32 μm, and even more preferably at most 30 μm. In some embodiments, the glass fibers have a cross-sectional longest dimension of 15 μm to 35 μm, preferably 20 μm to 30 μm, and even more preferably 25 μm to 29 μm. In some embodiments, the glass fibers have a cross-sectional shortest dimension of at least 4 μm, preferably at least 5 μm, more preferably at least 6 μm, and even more preferably at least 7 μm. Additionally or alternatively, in some embodiments, the glass fibers have a cross-sectional shortest dimension of at most 25 μm, preferably at most 20 μm, more preferably at most 17 μm, and even more preferably at most 15 μm. In some embodiments, the glass fiber has a shortest cross-sectional diameter of 5 μm to 20 μm, preferably 5 μm to 15 μm, and more preferably 7 μm to 11 μm.

[0090] According to certain embodiments, the glass fibers may be coated on their surfaces with a material to prevent reaction between the polymer of the polymer composition (C) and other ingredients and / or to improve the degree of impregnation / adhesion to the polymer. The coating material may change the overall flowability, impact strength, etc. of the glass fiber reinforced polymer composition. Materials suitable for coating the glass fibers and affecting the flowability, impact strength, etc. of the glass fiber reinforced polymer composition are well known to those skilled in the art and may be selected without undue experimentation depending on the desired properties of the resulting composition.

[0091] In addition to the above-mentioned flat glass fibers, the polymer composition (C) may further comprise an additional reinforcing filler, which may be a fibrous or particulate filler.

[0092] Preferably, the additional reinforcing filler is selected from inorganic fillers (talc, mica, kaolin, calcium carbonate, calcium silicate, magnesium carbonate, glass flakes, glass beads, etc.), glass fibers (different from the glass fibers mentioned above), carbon fibers, synthetic polymer fibers, aramid fibers, aluminum fibers, titanium fibers, magnesium fibers, boron carbide fibers, rock wool fibers, steel fibers, wollastonite, etc. More preferably, it is selected from mica, kaolin, calcium silicate, magnesium carbonate, wollastonite and glass fibers different from the glass fibers mentioned above, having a non-circular cross section and a specific modulus of elasticity.

[0093] In the polymer composition (C), the flat glass fibers are advantageously present in an amount of at least 10% by weight, preferably at least 12% by weight, more preferably at least 15% by weight, even more preferably at least 17% by weight, even more preferably at least 18% by weight, even more preferably at least 20% by weight, most preferably at least 25% by weight, and even at least 30% by weight, based on the total weight of the polymer composition (C).

[0094] The flat glass fibers are advantageously present in an amount of at most 60% by weight, preferably at most 58% by weight, more preferably at most 55% by weight, even more preferably at most 50% by weight, even more preferably at most 48% by weight, most preferably at most 45% by weight, and even more preferably at most 40% by weight, based on the total weight of the polymer composition (C).

[0095] Preferably, the flat glass fibers are present in an amount ranging from 10 to 60% by weight, more preferably from 15 to 55% by weight, based on the total weight of the polymer composition (C).

[0096] The concentration of the flat glass fibers is 10% to 60% by weight. In some embodiments, the concentration of the flat glass fibers is 10% to 55% by weight, 10% to 50% by weight, 15% to 55% by weight, 25% to 45% by weight, or 30% to 40% by weight.

[0097] Metal Insert The metal of the metal insert can be, for example, bronze, aluminum, aluminum alloy, brass alloy, zinc, copper, copper alloy, lead, stainless steel, carbon steel or galvanized steel. Other metals can be used as the material of construction for the metal insert.

[0098] The metal insert may in particular be a plug connection element, a sensor or a conductor structure (in particular a lead frame), or it may be a metal strip or bar or other form of rigid conductor.

[0099] The plug connection element may in particular be a plug pin or a plug socket intended to be assembled together with a plastic component. Since the plug connection element is provided for connection to a corresponding plug connection element, e.g. a plug pin for connection to a corresponding plug socket, the plug connection element is intended to be only partially overmolded with the plastic component, leaving part of the surface of the plug connection element exposed, so that a plug connection can be established.

[0100] The sensor may in particular have an exposed area, i.e. an area that is not intended to be embedded in the plastic component, so that the sensor can be in direct contact with the surroundings and measure information about the surroundings without being obstructed by the plastic component. For example, the sensor may be a temperature sensor or an optical sensor.

[0101] The conductor structure may be, for example, a lead framework for a circuit having a plurality of electrical contacts for connecting electrical components and a plurality of lead connections for electrically connecting the contacts to each other. Such a lead framework is particularly embedded in an assembly (MP) so that at least a portion of the electrical contacts remain exposed, so that the electrical components can be connected to the contacts. Such a lead framework is used, for example, in automobiles to interconnect prefabricated electrical components to form circuits.

[0102] The conductor structure may in particular be a lead frame, which is understood as a metallic lead carrier in the form of a frame or comb used to manufacture chip packages for microchips or other electrical components.

[0103] Alternatively, the metal insert may be a structural member, such as a tubular insert for a compressor wheel assembly, intended to be used as a central part for engaging a rotatable shaft, for example in impellers for turbochargers and superchargers.

[0104] Additionally, metal inserts may be fasteners for plastic brackets, particularly threaded studs, threaded inserts, threaded nuts, etc. The fasteners may include opposing knurls and / or diamond knurls on the surface that is bonded to the plastic component. Alternatively or additionally, the fasteners may include a flat base, typically with a through hole, to increase the resistance to pulling out of the plastic part of the bracket.

[0105] Another possibility is that the metal insert may be a structural or conductive part of a stator or rotor component of an electric motor.

[0106] Assembly (MP) The metal insert of the assembly (MP) comprises the area of ​​its surface that is not covered by the plastic component, on which e.g. welding can be performed, or it can be used for electrical connections, or it can be utilized for any other function.

[0107] If the assembly (MP) is an insulating busbar, the metal insert may be a metal strip or bar. In the busbar of the present invention, the plastic component advantageously provides in particular electrical insulation, and possibly also mechanical strength and structural stability to facilitate the mounting technique.

[0108] Assembly (MP) - a metal tubular insert having a shaft bore extending from an inlet end to an outlet end opposite the inlet end, and including at least one engagement member for engaging a rotatable shaft; a compressor wheel member made from a polymer composition (C) molded onto a tubular insert and having a blade array; a compressor wheel assembly including:

[0109] The compressor wheel assembly of the present invention is used in applications such as turbochargers, superchargers, and the like. A shaft drives the compressor wheel in rotation in a direction such that the blade array draws in air axially and expels the air radially outward at a high pressure level into a chamber in the compressor housing. The compressed air is then delivered from the chamber to the intake manifold of an internal combustion engine for mixing with fuel and combustion, all as is well known. The compressor wheel assembly of the present invention desirably provides the efficiency of polymer construction without the problems of creep and distortion.

[0110] The assembly (MP) can be a plastic bracket of any possible three-dimensional shape, especially for use as a fixture.

[0111] The assembly (MP) may be part of a stator component of an electric motor, more specifically a stator segment suitable for housing high coil density magnet wire, with metal inserts providing electrical connections and plastic parts providing insulation, or it may be either an internal or external tilt rotor stator with insulation by plastic components. Additionally, the assembly (MP) may be the rotor of an electric motor.

[0112] How to manufacture an assembly (MP) Another object of the invention is a method for manufacturing the assembly (MP) detailed above, comprising assembling a metal insert and a plastic component.

[0113] The most widely used technique for manufacturing assemblies (MP) is insert molding. According to this technique, the method for manufacturing assemblies (MP) is as follows: Step 1: placing a pre-formed metal insert into a mold; Step 2: molding the polymer composition (C) in the mold containing the pre-formed metal insert; It is generally understood that if the surface of the insert is not clean, the adhesion between the plastic component and the insert may be reduced, so metal inserts are typically protected from sources of contamination such as dirt, dust, skin oils (hence the need to wear gloves when handling the insert), mold release agents, lubricants, etc.

[0114] According to certain embodiments, the first step may include preheating the metal insert. The optimum insert temperature will vary depending on both the material of the metal insert and the type of polymer composition (C) used. However, this preheating step is not essential and may be omitted.

[0115] Texturing or pre-treating the surface of the metal insert that is coated with the plastic component can improve adhesion either through mechanical interlocking or chemical phenomena.

[0116] It may therefore be advantageous to subject the surface of the metal insert to a plasma treatment, optionally in the presence of a compound that promotes adhesion; any type of adhesive compound may be used, such as a silane compound.

[0117] Thus, the first step may involve using a metal insert that has undergone any of such pretreatments before being placed in the mold.

[0118] Said second step of the method typically involves injecting the polymer composition (C) in the molten phase into a mold containing the insert, solidifying the polymer composition (C) in contact with the metal insert, and removing the resulting assembly (MP) from the mold.

[0119] Insert molding technology can utilize conventional single-shot injection molding equipment. The mold used must accommodate the metal insert and hold it in place while the molten polymer is injected.

[0120] Using Assembly (MP) As previously mentioned, the assemblies of the present invention are useful in a variety of industries and applications. They are particularly well suited for use as automotive components, especially under the hood, due to their ability to withstand thermal shock without significant damage.

[0121] Importantly, the assembly (MP) of the present invention, in particular the busbar or stator / rotor components of an electric motor according to the present invention, can be advantageously used in e-mobility applications.

[0122] To the extent that the disclosure of any patents, patent applications, and publications incorporated herein by reference contradicts the statements of this application to the extent that a term may be unclear, the statements of this application shall control.

[0123] The invention will now be described with reference to the following examples, the purposes of which are illustrative only and are not intended to limit the scope of the invention.

[0124] Preparation of polymer compositions Compounds containing the ingredients listed in the table below were made by melt compounding by extrusion using a Coperion® ZSK-26 extruder and prepared in pellet form.

[0125] [Table 1]

[0126] [Table 2]

[0127] [Table 3]

[0128] [Table 4]

[0129] [Table 5]

[0130] [Table 6]

[0131] Manufacturing metal-plastic assemblies by overmolding Thermal shock properties were quantified using two different molds (A and B) overmolded with metal inserts according to the following protocol.

[0132] Mold A Metal inserts were prepared using S50C carbon steel containing 0.50% carbon as specified in JIS G4051, measuring 60.7 mm in length, 8.4 mm in width, and 2.4 mm in thickness, with a corner radius of 0.50 mm. These metal inserts had two through holes in the thickness direction to hold them in the cavity of the injection molding tool.

[0133] The tool cavity was 64.0 mm long, 10.0 mm wide, and 4.0 mm thick and contained two pins to hold the metal piece. The pins were positioned so that the molten plastic completely covered the metal insert, with a thickness of 0.80 mm, excluding the gate. A side gate, 3.0 mm thick and 6.0 mm wide, was located at the distal end of the tool.

[0134] The plastic assemblies were injection molded using an injection molding machine, model SE50DU, manufactured by Sumitomo Heavy Industries, Ltd. This machine had a clamping force of 50 tons, an in-line screw diameter of 22 mm, and a 40 cm 3 It has a cylinder capacity of

[0135] Injection molding of the PPS compounds was carried out at a cylinder temperature of 310–315°C, a tool surface temperature of 150°C, an injection speed of 120–200 mm / s, and an injection pressure of 115–150 MPa, with the metal pieces pre-inserted into the mold and preheated to 150°C before insertion.

[0136] A plastic assembly containing a metal insert completely covered with PPA was used for thermal shock testing.

[0137] Mold B: Metal specimens were prepared from copper alloy 110, specified in ASTM B152 as containing 99.9% copper and 0.04% oxygen, measuring 130 mm in length, 9.5 mm in width, and 3.2 mm in thickness with a corner radius of 0.50 mm. The copper rods were nickel-plated to prevent oxidation during preheating (150°C), overmolding (melting temperatures up to 350°C), and thermal exposure. To hold the copper rods within the cavity, two steel end blocks were developed that held the two copper rods together and fit within the cavity as a four-part assembly. This allowed for flexibility in specimen design through end block customization.

[0138] The tool had a central cavity measuring 80.0 mm long, 12.5 mm wide, and 12.4 mm thick, and two cavities for holding steel end blocks. To prevent deflection due to injection pressure, there were also two 4.6 mm diameter pins (one on the core side and one on the cavity side) supporting two copper rods in the center. Two gating options were available: (i) two side gates near both ends of the length, or (ii) one side gate near one end of the length.

[0139] For injection molding of the metal-plastic assemblies, an injection molding machine, model Ti-55G2, manufactured by Toyo Machinery & Metal Co., Ltd., was used. This machine had a clamping force of 55 tons, an in-line screw diameter of 28 mm, and a 60 cm 3 It has a cylinder capacity of

[0140] Injection molding of the PPA compound was carried out at a cylinder temperature of 338°C, a tool surface temperature of 192°C, an injection speed of 45 mm / s, and an injection pressure of 110 MPa, with the metal pieces pre-inserted into the mold and pre-heated to 200°C before insertion.

[0141] A plastic assembly containing a metal insert completely covered with PPA was used for thermal shock testing.

[0142] Thermal Shock Test Equipment used: A Weiss Thermal Shock TS60 chamber was used to perform the thermal cycling tests. This apparatus consists of two independently controlled chambers: one at high temperature and the other at low temperature. The test specimens are subjected to a temperature shock by rapidly moving a movable basket between the high and low temperature chambers. The temperature of the high temperature chamber can be adjusted from +50°C to +220°C, while the low temperature chamber can be adjusted from -80°C to +70°C. The movable basket moves from one chamber to the other within 10 seconds.

[0143] Testing Procedure: A set of five specimens of each injection molding material was placed on an aluminum rack to allow free air movement around all four sides of the specimens, and the rack was then placed in a movable basket.

[0144] The following test protocol was set up on the thermal shock chamber. High temperature chamber T=+150℃ Cold chamber T=-40℃ Time in each chamber: 1 hour Number of cycles: 300 cycles

[0145] The thermal shock test apparatus was shut down each day, the specimens removed from the test chamber, and each specimen visually inspected for crack damage. If any specimen showed any such damage, the cracked specimen was removed from the test, and the number and date of completed cycles were recorded. After all specimens had been thoroughly inspected, any specimens that remained undamaged were returned to the thermal shock test chamber and the programmed cycle was resumed.

[0146] Data Reporting and Analysis: When all five specimens reached failure, the average number of cycles to failure was calculated, and the minimum and maximum number of cycles to failure for a given set of specimens was also reported.

[0147] The results are summarized below.

[0148] Table 7

Claims

1. A metal-plastic assembly [assembly (MP)] comprising: a metal insert having a surface; a plastic component in contact with at least part of said surface of said metal insert, (A) at least one polymer selected from the group consisting of a polyamide polymer [polymer (PA)] and a polyarylene sulfide polymer [polymer (PAS)]; (B) Flat glass fiber [fiber (FGF)] a plastic component manufactured from a polymer composition [composition (C)] comprising Including, - said assembly (MP) is an insulating busbar and said metal insert is a metal strip or bar, or said assembly (MP) a metal tubular insert having a shaft bore extending from an inlet end to an outlet end opposite said inlet end and including at least one engagement member for engaging a rotatable shaft; a compressor wheel member made from said polymer composition (C) moulded onto said tubular insert and having an array of blades; or - said assembly (MP) is a plastic bracket of any possible three-dimensional shape, for use as a mounting fixture, or - a metal-plastic assembly [Assembly (MP)], said assembly (MP) being part of a stator or rotor component of an electric motor.

2. Assembly (MP) according to claim 1, wherein said composition (C) comprises a toughening agent in an amount greater than 1% by weight and less than 30% by weight, based on the total weight of said composition (C).

3. 3. An assembly (MP) according to claim 1 or 2, wherein the metal of the metal insert is one of bronze, aluminium, aluminium alloy, brass alloy, zinc, copper, copper alloy, lead, stainless steel, carbon steel or galvanised steel.

4. 4. The assembly (MP) according to any one of claims 1 to 3, wherein the polymer composition (C) is a polyamide-based composition in which polymer (PA) is present in a total amount of more than 30 wt.-%, more than 35 wt.-%, more than 40 wt.-% or more than 45 wt.-%, based on the total weight of the polymer composition (C), and / or in a total amount of less than 95 wt.-%, in particular less than 90 wt.-%, less than 80 wt.-%, less than 70 wt.-% or less than 60 wt.-%, based on the total weight of the polymer composition (C).

5. The polymer (PA) of the polymer composition (C) comprises repeating units (R 1 ) derived from the polycondensation of a diamine and a diacid of the following formula (AABB): ＰＡ ) and / or units derived from the polycondensation of amino acids or lactams of the following formula (AB): -NR Ｈ -R ＡＢ -C(O)- (AB) (I) -NR Ｈ -R ＢＢ -NR Ｈ -C(O)-R ＡＡ -C(O)- (AABB) (-I) (In the formula, R Ｈ is hydrogen or a hydrocarbon group, preferably R Ｈ is hydrogen, and R ＡＢ , R ＢＢ , R ＡＡ are equal to or different from each other and are divalent hydrocarbon radicals optionally containing one or more heteroatoms. The repeating units (I) and (II) of the polyamide (PA) are a mixture (M1) comprising at least a diacid [acid (DA)] (or a derivative thereof) and at least a diamine [amine (NN)] (or a derivative thereof), mixtures (M2) comprising at least a lactam [lactam (L)], a mixture (M3) comprising at least aminocarboxylic acids [amino acids (AN)], and - combinations of these 5. The assembly of claim 4, wherein the mixture is a condensation product of at least one selected from:

6. The acid (DA) is - Phthalic acids including isophthalic acid (IA) and terephthalic acid (TA), 2,5-pyridinedicarboxylic acid, 2,4-pyridinedicarboxylic acid, 3,5-pyridinedicarboxylic acid, 2,2-bis(4-carboxyphenyl)propane, bis(4-carboxyphenyl)methane, 2,2-bis(4-carboxyphenyl)hexafluoropropane, 2,2-bis(4-carboxyphenyl)ketone, 4,4'-bis(4-carboxyphenyl)sulfone, 2,2-bis(3-carboxyphenyl)propane, bis(3-carboxyphenyl)methane, 2,2-bis(3-carboxyphenyl)propane an aromatic dicarboxylic acid [acid (AR)] containing two reactive carboxylic acid groups selected from (A) and (B) selected from (A) and (B) selected from (B ... - Oxalic acid (HOOC-COOH), malonic acid (HOOC-CH ２ —COOH), succinic acid [HOOC—(CH ２ ) ２ —COOH], glutaric acid [HOOC-(CH ２ ) ３ —COOH], 2,2-dimethyl-glutaric acid [HOOC-C(CH ３ ) ２ - (CH ２ ) ２ —COOH], adipic acid [HOOC-(CH ２ ) ４ —COOH], 2,4,4-trimethyl-adipic acid [HOOC-CH(CH ３ )-CH ２ -C(CH ３ ) ２ -CH ２ —COOH], pimelic acid [HOOC-(CH ２ ) ５ —COOH], suberic acid [HOOC-(CH ２ ) ６ —COOH], azelaic acid [HOOC-(CH ２ ) ７ —COOH], sebacic acid [HOOC-(CH ２ ) ８ —COOH], undecanedioic acid [HOOC-(CH ２ ) ９ —COOH], dodecanedioic acid [HOOC-(CH ２ ) １０ —COOH], tridecanedioic acid [HOOC-(CH ２ ) １１ —COOH], tetradecanedioic acid [HOOC-(CH ２ ) １２ —COOH], octadecanedioic acid [HOOC-(CH ２ ) １６ -COOH] and aliphatic dicarboxylic acids containing two reactive carboxylic acid groups [acids (AL)] selected from alicyclic radical-containing acids, in particular 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, optionally as cis or trans diastereoisomers in mixtures. and / or said amine (NN) is selected from the group consisting of aliphatic diamines (NNa), aromatic diamines (NNar) and mixtures thereof; said aliphatic diamines (NNa) may be or comprise aliphatic alkylenediamines (NNaa) having from 2 to 18 carbon atoms and / or may be or comprise cycloaliphatic diamines, i.e. diamines comprising an cycloaliphatic group having from 2 to 18 carbon atoms [amines (NNca)]; An assembly (MP) according to claim 5, wherein said aromatic diamine (NNar) is preferably selected from the group consisting of meta-phenylenediamine, meta-xylylenediamine and para-xylylenediamine.

7. The polyamide (PA) is (A1) A semi-aromatic polyamide, - at least an aromatic diacid (and its derivatives) according to claim 6, optionally in combination with an aliphatic diacid (and its derivatives) according to claim 6, and - at least an aliphatic diamine [amine (NNa)] (and derivatives thereof) according to claim 6 a semi-aromatic polyamide comprising, preferably consisting of, units which are the condensation product of a mixture comprising (A2) A semi-aromatic polyamide, - at least one aliphatic diacid (and its derivatives) according to claim 6, and - at least one aromatic diamine (and its derivatives) according to claim 6 a semi-aromatic polyamide comprising, and preferably consisting of, repeating units which are the condensation product of a mixture comprising is selected from the group consisting of (1) The polyamide (PA) of type (A1) is preferably (i) polyamides comprising, preferably consisting of, units which are the condensation product of a mixture of 1,6-diaminohexane and terephthalic acid, optionally in combination with isophthalic acid, i.e. the resulting polycondensation product is polyamide 6T or polyamide 6T / 6I; (ii) polyamides comprising, preferably consisting of, units which are the condensation product of a mixture of 1,6-diaminohexane, 1,10-decamethylenediamine, and optionally 1,3-bis-(aminomethyl)-cyclohexane, and terephthalic acid, i.e. the resulting polycondensation product is polyamide 6T / 10T or polyamide 6T / 10T / BACT, (iii) Polyamides comprising, preferably consisting of, units which are the condensation product of a mixture of 1,6-diaminohexane, adipic acid and terephthalic acid, optionally in combination with isophthalic acid, i.e. the resulting polycondensation product is polyamide 6T / 66 or polyamide 6T / 6I / 66; (iv) Polyamides comprising, preferably consisting of, units which are the condensation product of a mixture of 1,6-diaminohexane, 1,3-bis-(aminomethyl)-cyclohexane (BAC), 1,4-cyclohexanedicarboxylic acid (cis, trans or cis / trans mixtures) (CHDA), and terephthalic acid, i.e. the resulting polycondensation product is polyamide 6T / BACT / 6CHDA / BACCHDA. and (2) Assembly (MP) according to claim 6, wherein the polyamide of type (A2) is preferably a polyamide comprising, preferably consisting of, units which are the condensation product of a mixture of m-xylenediamine (MXDA) and adipic acid, i.e. the resulting polycondensation product is polyamide MXD6.

8. 4. The assembly (MP) according to claim 1, wherein the polymer composition (C) is a poly(arylene sulfide)-based composition in which the polymer (PAS) is present in a total amount of more than 30 wt.%, more than 35 wt.%, more than 40 wt.%, or more than 45 wt.%, based on the total weight of the polymer composition (C), and / or the polymer (PAS) is present in a total amount of less than 95 wt.%, in particular less than 90 wt.%, less than 80 wt.%, less than 70 wt.%, or less than 60 wt.%, based on the total weight of the polymer composition (C).

9. The polymer (PAS) has the following formula: [-Ar １ -S-] (R ＰＡＳ１ ) (In the formula, -Ar １ -teeth, 【Chemistry 1】 and wherein: - R is in each case C １ ~C １２ Alkyl group, C ７ ~C ２４ Alkylaryl group, C ７ ~C ２４ Aralkyl group, C ６ ~C ２４ Arylene group and C ６ ~C １８ aryloxy groups; - T is a bond, -CO-, -SO ２ -, -O-, -C(CH ３ ) ２ -, -C(CF ３ ) ２ -, phenyl and -CH ２ - selected from the group consisting of i, at each occurrence, is an independently selected integer from 0 to 4; j, at each occurrence, is an independently selected integer from 0 to 3; -Ar １ is preferably of the following formula: 【Chemistry 2】 and even more preferably, -Ar １ - is represented by any of formulas (a-1), (a-2), and (a-3), and i is zero. The repeating unit (R ＰＡＳ１ Assembly (MP) according to claim 8, comprising:

10. The polymer (PAS) has the formula: 【Transformation 3】 Units of (R ＰＡＳ１ ) a polymer (PPS) having the formula: 【Chemistry 4】 The polymer (PPS) may additionally contain any unit of the following: ＰＰＳ－ｍ ) and / or (R ＰＰＳ－ｏ The repeating unit (R ＰＰＳ－ｍ ) and / or (R ＰＰＳ－ｏ The total concentration of ＰＰＳ ), (R ＰＰＳ－ｍ ) and (R ＰＰＳ－ｏ 10. The assembly (MP) of claim 9, wherein the amount of hydroxybenzoates is at most 10 mol %, at most 5 mol %, at most 3 mol %, at most 1 mol %, based on the total amount of hydroxybenzoates.

11. 11. The assembly (MP) according to any one of claims 1 to 10, wherein the flat glass fibers have a non-circular cross section selected from an elliptical cross section, an oval cross section, a rectangular cross section, a cross section in which a semicircle is connected to both short sides of a rectangle, and a cocoon-shaped cross section, and / or the flat glass fibers have an aspect ratio, which is the ratio between the longest dimension of the cross section and the shortest dimension of the cross section, of 1.0 to 10, preferably 1.5 to 6.0, more preferably 2.0 to 5.0, and most preferably 3.0 to 4.

0.

12. Assembly (MP) according to any one of the preceding claims, wherein the metal insert of said assembly (MP) comprises an area of ​​its surface that is not covered by said plastic component.

13. A method for manufacturing an assembly (MP) according to any one of claims 1 to 12, comprising assembling said metal insert and said plastic component.

14. Step 1: Placing a pre-formed metal insert into a mold; Step 2: molding the polymer composition (C) in the mold containing the pre-formed metal insert; 14. The method of claim 13, comprising:

15. Use of an assembly (MP) according to any one of claims 1 to 12 in automotive applications, in particular e-mobility applications.

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