Laser-transparent compositions and molded articles made therefrom

Abstract

The present invention provides a laser-transparent composition that enables laser welding. [Solution] A polyester polymer composition comprising one or more nucleating agents and optionally reinforcing fibers is described. The polyester polymer may be, for example, polybutylene terephthalate. The polymer composition is formulated to be substantially transparent at specific wavelengths of light. As a result, the polyester polymer composition is well suited for use in laser transmission welding, in which a laser beam passes through the polymer composition and forms a weld on adjacent surfaces. In one embodiment, a masterbatch of black pigment may be added to the composition to further improve the transmission properties.

Description

[Background technology]

[0001]

[0001] Engineering thermoplastics and elastomers are often used in a wide variety of applications to produce molded parts and molded products. For example, polyester polymers and polyester elastomers are used to produce all kinds of molded products, such as injection-molded products and blow-molded products. Polyester polymer compositions can be formulated, for example, to provide chemical resistance and excellent strength properties, and if polyester elastomers are included, they can be made flexible. Particularly advantageous is that polyester polymers can be melt-processed due to their thermoplastic properties. In addition, polyester polymers can be reused and reprocessed.

[0002]

[0002] Polyester polymers are particularly well suited for producing molded articles of any suitable shape or size. Such molded articles can be made by injection molding, thermoforming, or any other suitable melting method. In many applications, the molded articles are then bonded to adjacent materials in order to be incorporated into a product or system. Bonding can be done by using adhesives, by using ultrasonic energy, or by using mechanical fasteners. In certain applications, a preferred method for bonding or attaching two parts together is laser welding. The use of laser welding is not only relatively simple but also extremely precise and typically does not cause any structural damage to the parts.

[0003]

[0003] In one particular type of laser welding, often referred to as laser transmission welding, two polymer articles are placed in contact with each other, and laser energy is transmitted through the first molded article and then absorbed by the second article, thereby forming a weld. In this type of welding, for example, the first molded article is formulated to be laser-transparent. For example, the first molded article must allow a significant portion of the laser light to pass through and then be absorbed by the second molded article. When the laser energy comes into contact with the second molded article, the second molded article absorbs the energy, causing a localized temperature rise, which in turn softens and flows the polymer material used to form the second molded article. A weld is then formed, allowing the laser-transparent molded article to bond to the laser-absorbent molded article. [Overview of the initiative] [Problems that the invention aims to solve]

[0004]

[0004] In order for laser transmission welding to be successful, the laser-transmissive molded article must have relatively high laser transmittance at the wavelength in which the laser beam operates. Various efforts have been made to produce molded articles from polyester polymers with high laser transmittance. However, problems have arisen in whether polyester polymer articles with sufficient laser transmittance can be produced, especially when the polyester polymer composition contains reinforcing fibers. Reinforcing fibers can cause significant light scattering, for example, which unfavorably interferes with the welding process. Therefore, there is a need for fiber-reinforced polyester polymer compositions that are also transmittance to light at the desired wavelength. [Means for solving the problem]

[0005]

[0005] Generally, the disclosure of the present invention is directed toward polyester polymer compositions containing reinforcing fibers having excellent transmission properties at specific wavelengths of light. For example, the polymer compositions of the present disclosure can be formulated to be laser-transmissive for use in laser transmission welding procedures.

[0006]

[0006] In one embodiment, the disclosure is directed to a laser-permeable composition comprising at least one polyester polymer. The polyester polymer may include a polybutylene terephthalate polymer. The polybutylene terephthalate polymer may be present in the polymer composition in amounts, for example, more than about 40% by weight, for example more than about 50% by weight, for example more than about 60% by weight, and generally less than about 85% by weight. The polymer composition further contains reinforcing fibers. The reinforcing fibers may be present in the polymer composition in amounts, for example, more than about 5% to about 55% by weight, for example more than about 10% to about 38% by weight. The reinforcing fibers may include glass fibers.

[0007]

[0007] According to the present disclosure, the polymer composition further contains at least one nucleating agent. The at least one nucleating agent may include a benzoate, a salt of a carboxylic acid, or a mixture thereof. The polymer composition may have at least 40% laser transmittance when measured at a wavelength of 980 nm and a thickness of 1.5 mm. In addition, the polymer composition may have a tensile strength greater than about 75 MPa.

[0008]

[0008] In one embodiment, the laser-penetrating composition contains at least two nucleating agents. The first nucleating agent may contain a benzoate, and the second nucleating agent may contain a salt of a carboxylic acid. The salt of the carboxylic acid may be a salt of an aliphatic carboxylic acid having a carbon chain length of about 16 to about 50 carbon atoms, for example, about 18 to about 30 carbon atoms. The salt of the carboxylic acid may be an alkali or alkaline earth metal salt of the carboxylic acid. In one embodiment, the second nucleating agent may be a sodium salt of montanic acid. On the other hand, the benzoate may also contain an alkali or alkaline earth metal salt of benzoic acid. For example, in one embodiment, the first nucleating agent may contain sodium benzoate.

[0009]

[0009] In one embodiment, each nucleating agent contained in the polymer composition may be present in an amount of less than about 1.5% by weight, and generally in an amount greater than about 0.001% by weight. When both benzoates and carboxylic acid salts are present, the weight ratio of benzoates to carboxylic acid salts is about 1:1 to about 1:4, for example, about 1:1.5 to about 1:3.

[0010]

[0010] In one embodiment, the polymer composition may have a laser transmittance at a wavelength of 980 nm of about 40% or more when measured at a thickness of 1.5 mm, and 50% or more when measured at a thickness of 1 mm. The polymer composition may have a tensile strength greater than about 75 MPa, for example greater than about 100 MPa, for example greater than about 120 MPa, and generally less than about 400 MPa.

[0011]

[0011] In one embodiment, the polymer composition may also contain a colorant. For example, the polymer composition may contain a black pigment or dye, which may have a black appearance while maintaining excellent laser transmission properties. The black pigment or dye may be present in the polymer composition in an amount of about 0.1 to about 4% by weight.

[0012]

[0012] The disclosure of the present invention is also directed toward molded articles formed from polymer compositions as described above. The molded articles may be laser-welded to adjacent surfaces or components. In one embodiment, the molded article is a housing for a sensor. The sensor may be, for example, part of an advanced driver assistance system.

[0013]

[0013] The disclosure of the present invention is also directed toward a method for attaching polymer articles to adjacent surfaces. The method involves bringing a molded article made from a laser-transparent composition as described above into contact with a laser beam. The laser beam propagates through the molded article and comes into contact with adjacent surfaces formed from a laser-weldable polymer composition. The laser beam causes a localized temperature rise at the adjacent surfaces to form a weld. In one embodiment, the weld attaches the molded article to the adjacent surfaces.

[0014]

[0014] Other features and forms of this disclosure will be discussed in more detail below.

[0015] The remainder of this specification, including references to the attached drawings, provides a more detailed description of the complete and feasible disclosure of the present invention. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a perspective view illustrating a laser welding process that can be performed in accordance with this disclosure. [Figure 2] Figure 2 is a perspective view illustrating a molded polymer plaque created to standardize the determination of laser transmission. Figure 2 shows the smallest different sample arrangements to be tested. [Modes for carrying out the invention]

[0016]

[0016] The repeated use of reference symbols in this specification and drawings is intended to represent the same or similar features or elements of the present invention.

[0017] Those skilled in the art will understand that the discussion of the present invention is merely a description of exemplary embodiments and is not intended to limit the broader forms of the present disclosure.

[0017]

[0018] Polyester polymer compositions, particularly fiber-reinforced polybutylene terephthalate compositions, possess a diverse range of desirable physical, mechanical, and electrical properties, along with excellent chemical and environmental resistance. Polyester compositions are used in all kinds of applications and represent a rapidly growing market for use in producing advanced drive assist systems. Polyester compositions are well-suited, for example, to producing all kinds of different types of electrical sensors. In these applications, a preferred method for assembling different components is to use laser welding. For example, the use of laser transmission welding has become very popular in recent years. During laser transmission welding, two joining partners are brought into contact and held together. The assembly includes an upper part and a lower part. The upper part of the assembly is formulated to be transparent to the wavelength on which the irradiating laser operates. However, the lower part is formulated to be laser absorbent. In this manner, the laser can pass through the upper part and be absorbed by the lower part, which results in localized heating at the boundary between the two parts, leading to the melting of both parts by thermal conduction.

[0018]

[0019] The present disclosure is directed in particular to formulating polyester compositions that are laser transparent and may optionally contain reinforcing fibers. Polyesters such as polybutylene terephthalate polymers have excellent and desirable physical properties, but these polymers have significantly lower light transmittance in the near-infrared region compared to many other thermoplastic polymers. As a result, the use of polyester compositions in laser transmission applications has heretofore been somewhat limited, especially when the thickness of the part increases. In addition, the addition of reinforcing fibers further reduces the laser transmittance of the polymer. However, according to the present disclosure, it has been discovered that adding one or more nucleating agents to a polyester polymer composition can dramatically and unexpectedly improve the laser transmission properties of molded parts made from such compositions. While not clear, it is believed that the nucleating agent produces smaller spherulites that allow the passage of near-infrared light. However, nucleating agents may have a detrimental effect on the mechanical properties of various polyester polymers. Consequently, the present disclosure is directed to selecting specific nucleating agents in specific amounts that increase laser transmittance without degrading the strength of the polymer composition.

[0019]

[0020] The polymer composition of the present disclosure generally contains at least one polyester polymer, optionally reinforcing fibers, and one or more nucleating agents. The polyester polymer may be a polybutylene terephthalate polymer. The polybutylene terephthalate polymer is generally present in the polymer composition in an amount greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 55% by weight, such as greater than about 60% by weight, such as greater than about 65% by weight, and generally in an amount less than about 95% by weight, such as less than about 90% by weight, such as less than about 80% by weight.

[0020]

[0021] In one embodiment, the polymer composition contains only a single polyester polymer, which is a polybutylene terephthalate polymer. Alternatively, other polyester polymers may be present in the polymer composition. For example, in one form, the polybutylene terephthalate polymer can be combined with a polyethylene terephthalate polymer. In addition to at least one polyester polymer, the polymer composition may optionally contain reinforcing fibers, such as glass fibers. According to the present disclosure, the polymer composition further contains one or more nucleating agents. It has been found that the nucleating agent dramatically improves the transmission properties of the polymer composition at a wavelength that facilitates laser welding without adversely affecting the mechanical properties of a molded article produced from the polymer composition.

[0021]

[0022] The polymer composition of the present disclosure may have a laser transmittance of at least about 40%, for example, when measured at a wavelength of 980 nm and a thickness of 1.5 mm. A standardized test for measuring laser transmittance is performed by first molding a plaque having dimensions of 60 mm×60 mm×1 mm or 1.5 mm using the polymer composition. When a wavelength of 980 nm is produced by an LPKF TMG-3 model transmittance measuring device and there is no obstacle blocking the path through which the laser light transmits, it is considered to have a laser transmittance of 100%. To determine the laser transmittance of the polymer composition, a polymer plaque is placed on a laser detector and transmission is tested in at least five different positions. At least two positions near the inlet, one position in the center, and two positions away from the inlet are all measured for laser transmission, and all the measurements are averaged to determine the final laser transmittance of the polymer composition.

[0022]

[0023] For example, a polymer composition may exhibit a transmittance of at least 40%, e.g., at least 42%, e.g., at least 45%, e.g., at least 48%, at a wavelength of 980 nm and a thickness of 1.5 mm. When measured at a thickness of 1 mm, the polymer compositions disclosed in the present invention may exhibit a transmittance of greater than about 50%, e.g., greater than about 55%, e.g., greater than about 60%, e.g., greater than about 62%, at a wavelength of 980 nm. The polymer compositions may exhibit the above transmittance properties while having excellent tensile strength. The tensile strength can be modified or controlled based on the amount of reinforcing fibers present in the polymer composition. Generally, the polymer compositions may exhibit a tensile strength greater than about 75 MPa. For example, the tensile strength may be greater than about 100 MPa, e.g., greater than about 120 MPa, e.g., greater than about 125 MPa, e.g., greater than about 130 MPa, e.g., greater than about 135 MPa, e.g., greater than about 140 MPa, e.g., greater than about 145 MPa, and generally less than about 300 MPa, e.g., less than about 200 MPa.

[0023]

[0024] Referring to Figure 1, a diagram illustrating the transmission welding process is presented for illustrative purposes only. Referring to Figure 1, it is shown that the assembly includes a first molded part 10 placed adjacent to a second molded part 20. A laser device 30 emitting a laser beam 40 is also illustrated. As shown in Figure 1, in this embodiment, the laser 30 travels across the width of the first molded part 10 and the second molded part 20. The first molded part 10 is relatively transparent to the laser beam 40, while the second molded part 20 is formulated to absorb the laser beam. In this manner, as shown in Figure 1, a substantial portion of the laser beam 40 passes through the first molded part 10 and comes into contact with the second molded part 20. The second molded part 20 then absorbs the laser energy and experiences a localized temperature rise, which melts both the first molded part 10 and the second molded part 20, causing them to bond together.

[0024]

[0025] In the embodiment illustrated in Figure 1, the first molded part 10 is shown to be translucent to better illustrate the laser transmission process. However, the polymer composition formulated according to this disclosure may have any preferred color, such as black.

[0025]

[0026] As described above, polymer compositions generally contain thermoplastic polymers, and in particular polyester polymers. Suitable polyesters for use herein are derived from aliphatic or alicyclic diols containing 2 to about 10 carbon atoms, or mixtures thereof, and aromatic dicarboxylic acids, i.e., polyalkylene terephthalates.

[0026]

[0027] Polyesters derived from alicyclic diols and aromatic dicarboxylic acids are prepared, for example, by condensing either a cis or trans isomer (or a mixture thereof) of 1,4-cyclohexanedimethanol with an aromatic dicarboxylic acid.

[0027]

[0028] Examples of aromatic dicarboxylic acids include isophthalic acid or terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4'-dicarboxydiphenyl ether, and mixtures thereof. All of these acids contain at least one aromatic nucleus. The condensed ring may also be present, for example, in 1,4- or 1,5- or 2,6-naphthalenedicarboxylic acid. In one embodiment, the dicarboxylic acid is terephthalic acid, or a mixture of terephthalic acid and isophthalic acid.

[0028]

[0029] Examples of polyesters that can be used in polymer compositions include polyethylene terephthalate, polybutylene terephthalate, mixtures thereof, and copolymers thereof.

[0029]

[0030] In one embodiment, a polyester polymer, such as polybutylene terephthalate polymer, contains a relatively small amount of carboxyl-terminated groups. For example, a polyester polymer may contain carboxyl-terminated groups in an amount less than about 20 mmol / kg, for example less than about 18 mmol / kg, for example less than about 15 mmol / kg, and generally greater than about 1 mmol / kg. The amount of carboxyl-terminated groups can also be minimized in a polyester polymer using various techniques. For example, in one embodiment, a polyester polymer may be contacted with an alcohol, such as benzyl alcohol, to reduce the amount of carboxyl-terminated groups, or the condensation products of 4,4'-(1-methylethylidene)bispolymer, which are phenols, with epoxy resins, such as 2,2-bis(p-hydroxyphenyl)propane and similar isomers, and 2,2'-[(1-methylethylidene)bis(4,1-phenyleneoxymethylene)]bis(oxirane), respectively.

[0030]

[0031] Polyester polymers or polybutylene terephthalate polymers, when tested at 250°C and with a load of 2.16 kg, generally exhibit a yield of approximately 9 cm. 3 Larger than 10 minutes, for example, about 15 cm 3 Larger than 10 minutes, for example, about 20cm 3 Larger than 10 minutes, and generally about 120 cm. 3 Less than 10 minutes, for example, about 100cm 3 / Less than 10 minutes, for example, about 70cm 3 Less than 10 minutes, for example, about 50cm 3 It may have a melt flow rate of less than 10 minutes.

[0031]

[0032] The polymer composition may also contain reinforcing fibers dispersed in a thermoplastic polymer matrix. Advantageously usable reinforcing fibers include mineral fibers, such as glass fibers or polymer fibers, and specifically organic high-elasticity fibers, such as aramid fibers.

[0032]

[0033] These fibers may be in a modified or unmodified form, and may be sized or chemically treated, for example, to improve adhesion to plastics. Glass fibers are particularly preferred.

[0033]

[0034] Reinforcing fibers, such as glass fibers, may be coated with a sizing composition to protect the fibers and to further improve adhesion between the fibers and the matrix material. The sizing composition typically comprises a silane, a film-forming agent, a lubricant, a wetting agent, an adhesive, optionally an antistatic agent and a plasticizer, an emulsifier, and optionally further additives.

[0034]

[0035] Specific examples of silanes include aminosilanes, such as 3-trimethoxysilylpropylamine, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, N-(3-trimethoxysilanylpropyl)ethane-1,2-diamine, 3-(2-aminoethyl-amino)propyltrimethoxysilane, and N-[3-(trimethoxysilyl)propyl]-1,2-ethane-diamine.

[0035]

[0036] Film-forming agents include, for example, polyvinyl acetate, polyester, and polyurethane.

[0037] The sizing composition applied to reinforcing fibers may contain not only a silane sizing agent but also a hydrolysis resistant agent. The hydrolysis resistant agent may be, for example, a glycidyl ester type epoxy resin. For example, the glycidyl ester type epoxy resin may be a monoglycidyl ester or a diglycidyl ester. Examples of usable glycidyl ester type epoxy resins include glycidyl acrylate, glycidyl methacrylate, diglycidyl phthalate, diglycidyl methyltetrahydrophthalate, or mixtures thereof.

[0036]

[0038] In one embodiment, the sizing composition contains a silane, a glycidyl ester type epoxy resin, a second epoxy resin, a urethane resin, an acrylic resin, a lubricant, and an antistatic agent. The second type epoxy resin may be, for example, a bisphenol A type epoxy resin. A hydrolysis resistant agent may be present in the sizing composition in a weight ratio of about 5:1 to about 1:1 relative to the silane sizing agent, for example, in a weight ratio of about 4:1 to about 2:1.

[0037]

[0039] Reinforcing fibers can be mixed into the polymer matrix, for example, using an extruder or kneader.

[0040] The fiber diameter may vary depending on the specific fiber used, and further depending on whether the fiber is in shredded or continuous form. The fiber may have a diameter of, for example, about 5 μm to about 100 μm, for example, about 5 μm to about 50 μm, for example, about 5 μm to about 12 μm. The fiber length may vary depending on the specific application. The fiber may have an average length of, for example, greater than about 0.5 mm, for example, greater than about 1 mm, for example, greater than about 1.5 mm, for example, greater than about 2.5 mm. The fiber length may generally be less than about 8 mm, for example, less than about 7 mm, for example, less than about 5.5 mm, for example, less than about 4 mm.

[0038]

[0041] Generally, reinforcing fibers are present in the polymer composition in an amount sufficient to increase the tensile strength of the composition. For example, the reinforcing fibers may be present in the polymer composition in an amount greater than about 2% by weight, for example greater than about 5% by weight, for example greater than about 10% by weight, for example greater than about 15% by weight, for example greater than about 20% by weight. Generally, the reinforcing fibers are present in an amount less than about 55% by weight, for example less than about 50% by weight, for example less than about 45% by weight, for example less than about 40% by weight, for example less than about 35% by weight, for example less than about 30% by weight.

[0039]

[0042] In addition to one or more thermoplastic polymers and any reinforcing fibers, the polymer compositions of the present disclosure contain one or more nucleating agents. For example, one nucleating agent that has been found to be particularly well suited for use in the polymer compositions of the present disclosure is a benzoate, and more specifically a benzoate. The benzoate may be, for example, an alkali or alkaline earth metal salt of benzoic acid. In one embodiment, the nucleating agent may be sodium benzoate.

[0040]

[0043] Another nucleating agent that has been found to be particularly well suited for use in this disclosure is a salt of one or more carboxylic acids, for example, a salt of one or more fatty acids. For example, the nucleating agent may comprise a salt of one or more aliphatic carboxylic acids. The carboxylic acid may have a relatively long carbon chain length. For example, the carboxylic acid may have a carbon chain length of about 14 to about 50 carbon atoms, for example, a carbon chain length of about 24 to about 34 carbon atoms. The carboxylic acid may be an aliphatic carboxylic acid or a linear carboxylic acid. The salt of the carboxylic acid may be an alkali or alkaline earth metal salt.

[0041]

[0044] In one particular embodiment, the nucleating agent may be a salt of montanic acid, for example, a sodium salt and / or a calcium salt of montanic acid. Examples of montanic acid include blends of carboxylic acids having carbon chain lengths of about 24 to about 34 carbon atoms, for example, about 28 to about 32 carbon atoms.

[0042]

[0045] In one embodiment, the nucleating agent is a sodium salt of a phosphorus compound. A preferred type of sodium salt nucleating agent is the sodium salt of 2,4,8,10-tetra(tert-butyl)-6-hydroxy-12H-dibenzo[d,g][1,3,2]dioxaphosphosine 6-oxide. A commercially available example of such a preferred sodium salt is available from Adeka under the name ADK STAB NA-11, and has the following general structure:

[0043] [ka]

[0044]

[0046] In one embodiment, the nucleating agent may include a sorbitol-type nucleating agent. Examples of sorbitol-based nucleating agents include 1,3:2,4-dibenzylidene sorbitol, 1,3:2,4-di(methylbenzylidene) sorbitol, 1,3:2,4-di(ethylbenzylidene) sorbitol, and 1,3:2,4-bis(3,4-dimethylbenzylidene) sorbitol. A suitable sorbitol-type nucleating agent is Miliken NX8000i, which is commercially available from Miliken Chemical.

[0045]

[0047] Each nucleating agent may be present in the polymer composition in an amount of less than about 3% by weight, for example, less than about 1.5% by weight, for example, less than about 1.2% by weight, for example, less than about 0.8% by weight, and generally in an amount greater than about 0.05% by weight, for example, greater than about 0.1% by weight, for example, greater than about 0.15% by weight.

[0046]

[0048] In one particular embodiment, the polymer composition contains one or more nucleating agents. For example, the polymer composition may contain a benzoate, such as sodium benzoate, in combination with one or more carboxylic acid salts as described above. In one embodiment, one or more carboxylic acid salts may be present in the polymer composition in amounts greater than the amount of sodium benzoate present. For example, the weight ratio of one or more carboxylic acid salts to sodium benzoate may be about 4:1 to about 1:1, for example, about 3:1 to about 1.5:1. In one particular embodiment, the ratio of one or more carboxylic acid salts to sodium benzoate is about 2.5:1 to about 1.5:1.

[0047]

[0049] In one embodiment, the polyester polymer composition may contain a carbodiimide compound. The carbodiimide compound may have a carbodiimide group (-N=C=N-) in its molecule. The carbodiimide compound can provide hydrolysis resistance. Applicable carbodiimide compounds include aliphatic carbodiimide compounds having an aliphatic main chain, alicyclic carbodiimide compounds having an alicyclic main chain, and aromatic carbodiimide compounds having an aromatic main chain.

[0048]

[0050] Examples of aliphatic carbodiimide compounds include diisopropylcarbodiimide and dioctyldecylcarbodiimide. Examples of alicyclic carbodiimide compounds include dicyclohexylcarbodiimide.

[0049]

[0051] Examples of aromatic carbodiimide compounds include mono or dicarbodiimide compounds, such as diphenylcarbodiimide, di-2,6-dimethylphenylcarbodiimide, N-tolyl-N'-phenylcarbodiimide, di-p-nitrophenylcarbodiimide, di-p-aminophenylcarbodiimide, di-p-hydroxyphenylcarbodiimide, di-p-chlorophenylcarbodiimide, di-p-methoxyphenylcarbodiimide, di-3,4-dichlorophenylcarbodiimide, di-2,5-dichlorophenylcarbodiimide, di-o-chlorophenylcarbodiimide, p-phenylene-bis-di-o-tolylcarbodiimide, p-phenylene-bis-dicyclohexylcarbodiimide, and p-phenylene-bis-di-p-chloro Examples include phenylcarbodiimides, or ethylene-bis-diphenylcarbodiimides; and polycarbodiimide compounds, such as poly(4,4'-diphenylmethanecarbodiimide), poly(3,5'-dimethyl-4,4'-biphenylmethanecarbodiimide), poly(p-phenylenecarbodiimide), poly(m-phenylenecarbodiimide), poly(3,5'-dimethyl-4,4'-diphenylmethanecarbodiimide), poly(naphthylenecarbodiimide), poly(1,3-diisopropylphenylenecarbodiimide), poly(1-methyl-3,5-diisopropylphenylenecarbodiimide), poly(1,3,5-triethylphenylenecarbodiimide), or poly(triisopropylphenylenecarbodiimide). These compounds can be used in combinations of two or more of these compounds. Among these, particularly preferred ones that can be used are di-2,6-dimethylphenylcarbodiimide, poly(4,4'-diphenylmethanecarbodiimide), poly(phenylenecarbodiimide), and poly(triisopropylphenylenecarbodiimide).

[0050]

[0052] In one form, a carbodiimide compound is a polycarbodiimide. For example, a polycarbodiimide may have a weight-average molecular weight of about 10,000 g / mol or greater, and generally less than about 100,000 g / mol. Examples of polycarbodiimides include Stabaxol KE9193 and Stabaxol P100 by Lanxess, and Lubio AS3-SP by Schaeffe Additive Systems.

[0051]

[0053] The carbodiimide compound may be present in the polymer composition in amounts greater than about 0.3% by weight, for example, greater than about 0.8% by weight, and generally in amounts less than about 4% by weight, for example, less than about 3% by weight, for example, less than 1.8% by weight.

[0052]

[0054] Among the specific advantages, the polymer compositions of this disclosure may contain one or more colorants and still retain desirable laser transmission properties. The colorants may be dyes, pigments, or combinations thereof. The polymer compositions can be formulated to have any suitable color. In one embodiment, for example, the polymer composition may be formulated to have a black color or black appearance.

[0053]

[0055] In one embodiment, one or more colorants may be added to the polymer composition as a masterbatch. In one embodiment, the masterbatch may contain a black dye in an amount of about 30 to about 70% by weight. The black dye may be any suitable black colorant, an example of which is Clariant's RENOL NB93447125. The addition of a black colorant to the masterbatch does not degrade laser transmittance. When the colorant is added to the polymer composition as a masterbatch, it can be combined with a carrier, such as a carrier polymer. In one embodiment, the carrier may be a copolyester elastomer.

[0054]

[0056] Each colorant may be present in the polymer composition in an amount generally less than about 3% by weight, for example less than about 2% by weight, for example less than about 1% by weight, and generally more than about 0.01% by weight, for example more than about 0.1% by weight. When added as a masterbatch, the masterbatch may be added to the polymer composition in an amount generally of about 1 to about 5% by weight.

[0055]

[0057] The polymer composition may also contain one or more lubricants. For example, fatty acid esters may be present as lubricants. Fatty acid esters can also be obtained by oxidative bleaching of crude natural waxes followed by esterification of fatty acids with alcohols. Alcohols typically have 1 to 4 hydroxyl groups and 2 to 20 carbon atoms. If the alcohol is polyfunctional (e.g., has 2 to 4 hydroxyl groups), a carbon atom count of 2 to 8 is particularly desirable. Particularly preferred polyfunctional alcohols include dihydric alcohols (e.g., ethylene glycol, propylene glycol, butylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and 1,4-cyclohexanediol), trihydric alcohols (e.g., glycerol and trimethylolpropane), and tetrahydric alcohols (e.g., pentaerythritol and erythritol). Aromatic alcohols may also be suitable, and examples include, for example, o-, m- and p-tolylcarbinol, chlorobenzyl alcohol, bromobenzyl alcohol, 2,4-dimethylbenzyl alcohol, 3,5-dimethylbenzyl alcohol, 2,3,5-cumobenzyl alcohol, 3,4,5-trimethylbenzyl alcohol, p-cumyl alcohol, 1,2-phthalyl alcohol, 1,3-bis(hydroxymethyl)benzene, 1,4-bis(hydroxymethyl)benzene, pseudocumenyl glycol, mesitylene glycol, and mesitylene glycerol. Particularly suitable fatty acid esters for use in the present invention are derived from montanic acid wax. For example, montanic acid may be partially esterified with butylene glycol, or partially saponified with calcium hydroxide. In one embodiment, the lubricant may be a combination of an ester of montanic acid and a polyol.

[0056]

[0058] Other known waxes can also be employed as lubricants. For example, amide waxes formed by the reaction of a fatty acid with a monoamine or diamine having 2 to 18 carbon atoms, particularly 2 to 8 carbon atoms (e.g., ethylenediamine) may potentially be employed. For example, ethylene bisamide wax is formed through the amidization reaction between ethylenediamine and a fatty acid, and this may potentially be employed. The fatty acid may be C 12 ~C 30 in the range, for example, stearic acid (C 18 fatty acid) can be used, and ethylene bisstearamide wax may be formed. Ethylene bisstearamide wax is commercially available from Lonza, Inc. under the trade name Acrawax® C, which has a distinct melting temperature of 142°C. Other ethylene bisamides include bisamides formed from lauric acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, oleostearic acid, myristic acid and undecalinic acid. Still other suitable amide waxes are N-(2-hydroxyethyl) 12-hydroxystearamide and N,N'-(ethylene bis) 12-hydroxystearamide, which are commercially available from CasChem, a division of Rutherford Chemicals LLC, under the trade names Paricin® 220 and Paricin® 285 respectively. Other waxes that can be used include polyethylene waxes.

[0057]

[0059] One or more lubricants may generally be present in the polymer composition in an amount greater than about 0.1% by weight, for example, greater than about 0.2% by weight, for example, greater than about 0.8% by weight, for example, greater than about 1% by weight. One or more lubricants may generally be present in an amount less than about 5% by weight, for example, less than about 4% by weight, for example, less than about 3.5% by weight.

[0058]

[0060] The polymer compositions of this disclosure may contain various other additives. For example, the polymer composition may contain at least one stabilizer. The stabilizer may include antioxidants, light stabilizers, such as ultraviolet light stabilizers and heat stabilizers.

[0059]

[0061] Steriohinable phenolic antioxidants may be used in the composition. Examples of such phenolic antioxidants include, for example, calcium bis(ethyl 3,5-di-tert-butyl-4-hydroxybenzylphosphonate) (Irganox® 1425); 1,4-dithio-,S,S-bis(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl) terephthalate (Cyanox® 1729); triethylene glycol bis(3-tert-butyl-4-hydroxy-5-methylhydrocinnamate); hexamethylene bis(ethyl 3,5-butyl-4-hydroxy-5-methylhydrocinnamate); and hexamethylene bis(ethyl 3,5-butyl-4-hydroxy-5-methylhydrocinnamate). Su(3,5-di-tert-butyl-4-hydroxyhydrocinnamate (Irganox® 259); 1,2-bis(3,5,di-tert-butyl-4-hydroxyhydrocinnamoyl)hydrazide (Irganox® 1024); 4,4'-di-tert-octyldifenamine (Naugalube® 438R); phosphonic acid (3,5-di-tert-butyl-4-hydroxybenzyl)-,dioctadecyl ester (Irganox® 1093); 1,3,5-trimethic acid Tyl-2,4,6-tris(3',5'-di-tert-butyl-4'hydroxybenzyl)benzene (Irganox® 1330); 2,4-bis(octylthio)-6-(4-hydroxy-3,5-di-tert-butylanilino)-1,3,5-triazine (Irganox® 565); isooctyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate (Irganox® 1135); octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate Ropionate (Irganox® 1076); 3,7-bis(1,1,3,3-tetramethylbutyl)-10H-phenothiazine (Irganox® LO3); 2,2'-methylenebis(4-methyl-6-tert-butylphenol) monoacrylate (Irganox® 3052); 2-tert-butyl-6-[1-(3-tert-butyl-2-hydroxy-5-methylphenyl)ethyl]-4-methylphenyl acrylate (Sumilizer® TM4039);2-[1-(2-hydroxy-3,5-di-tert-pentylphenyl)ethyl]-4,6-di-tert-pentylphenyl acrylate (Smilizer® GS); 1,3-dihydro-2H-benzimidazole (Smilizer® MB); 2-methyl-4,6-bis[(octylthio)methyl]phenol (Irganox® 1520); N,N'-trimethylenebis-[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionamide (Irganox® )1019); 4-n-octadecyloxy-2,6-diphenylphenol (Irganox® 1063); 2,2'-ethylidenebis[4,6-di-tert-butylphenol] (Irganox® 129); N,N'-hexamethylenebis(3,5-di-tert-butyl-4-hydroxyhydrocinnamamide) (Irganox® 1098); diethyl(3,5-di-tert-butyl-4-hydroxybenzyl)phosphonate (Irganox® 1222); 4, 4'-di-tert-octyldiphenylamine (Irganox® 5057); N-phenyl-1-naphthaleneamine (Irganox® L05); Tris[2-tert-butyl-4-(3-ter-butyl-4-hydroxy-6-methylphenylthio)-5-methylphenyl]phosphyt (Hostanox® OSP1); Zinc dinonyl dithiocarbamate (Hostanox® VP-ZNCS1); 3,9-bis[1,1-dimethyl-2-[(3-t [ert-butyl-4-hydroxy-5-methylphenyl)propionyloxy]ethyl]-2,4,8,10-tetraoxaspiro[5.5]undecane (Smilizer® AG80); pentaerythrityltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] (Irganox® 1010); ethylene-bis(oxyethylene)bis[3-(5-tert-butyl-4-hydroxy-m-tolyl)-propionate (Irganox® 245);Examples include 3,5-di-tert-butyl-4-hydroxytoluene (Lowinox BHT, Chemtura).

[0060]

[0062] Some examples of sterically hindered phenolic antioxidants suitable for use in the compositions of the present invention are triazine antioxidants having the following general formula:

[0061] [ka]

[0062] In each formula, R is independently a phenol group, which may be bonded to a triazine ring via a C1-C5 alkyl or ester substituent. Preferably, each R is one of the following formulas (I)-(III):

[0063] [ka]

[0064]

[0063] Commercially available examples of such triazine-based antioxidants include those obtained from American Cyanamid under the name Cyanox® 1790 (wherein each R group is represented by formula III), and those obtained from Ciba Specialty Chemicals under the names Irganox® 3114 (wherein each R group is represented by formula I) and Irganox® 3125 (wherein each R group is represented by formula II).

[0065]

[0064] The sterically hindered phenolic antioxidant may constitute about 0.01 wt.% to about 3 wt.% of the whole stabilized polymer composition, and in some embodiments, it may constitute about 0.05 wt.% to about 1 wt.%, and in some embodiments, about 0.05 wt.% to about 0.1 wt.%. In one embodiment, for example, the antioxidant includes pentaerythrityltetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate.

[0066]

[0065] Hindered amine light stabilizers ("HALS") may be used in the composition to extend its durability by inhibiting the degradation of the polyester composition. Suitable HALS compounds may be obtained from substituted piperidines, such as alkyl-substituted piperidyl, piperidinyl, piperazinone, and alkoxypiperidinyl compounds. For example, the hindered amine may be obtained from 2,2,6,6-tetraalkylpiperidinyl. Regardless of the compound from which it is derived, the hindered amine is typically an oligomeric or polymeric compound having a number average molecular weight of about 1,000 or higher, and in some embodiments, an oligomeric or polymeric compound having a number average molecular weight of about 1,000 to about 20,000, in some embodiments, about 1,500 to about 15,000, and in some embodiments, about 2,000 to about 5,000. Such compounds typically contain at least one 2,2,6,6-tetraalkylpiperidinyl group (e.g., 1 to 4) per polymer repeating unit.

[0067]

[0066] Although not intended to be limited by theory, high molecular weight hindered amines are considered to be relatively thermally stable and therefore can inhibit photodegradation even after exposure to extrusion conditions. One particularly suitable high molecular weight hindered amine has the following general structure:

[0068] [ka]

[0069] In the formula, p is 4 to 30, 4 to 20 in some embodiments and 4 to 10 in other embodiments. This oligomeric compound is commercially available from Clariant under the name Hostavin® N30 and has a number-average molecular weight of 1200.

[0070]

[0067] Another preferred high molecular weight hindered amine has the following structure:

[0071] [ka]

[0072] In the formula, n is 1 to 4, and R 30 These are independently hydrogen or CH3. Such oligomeric compounds are available from Adeka Palmarole SAS (a joint venture between Adeka and the Palmarole Group) under the ADK STAB® trademark LA-63(R 30 (This is CH3) and ADK STAB(registered trademark) LA-68(R 30 It is commercially available under the name (which is hydrogen).

[0073]

[0068] Other suitable examples of high molecular weight hindered amines include, for example, an oligomer of N-(2-hydroxyethyl)-2,2,6,6-tetramethyl-4-piperidinol with succinic acid (Tinuvin® 622 from Ciba Specialty Chemicals, MW=4000); an oligomer of cyanuric acid with N,N-di(2,2,6,6-tetramethyl-4-piperidyl)-hexamethylenediamine; and poly((6-morpholy) (S-triazine-2,4-diyl)(2,2,6,6-tetramethyl-4-piperidinyl)-iminohexamethylene-(2,2,6,6-tetramethyl-4-piperidinyl)-imino)(Cyasorb (registered trademark) UV3346, MW=1600 from Cytec); polymethylpropyl-3-oxy-[4(2,2,6,6-tetramethyl)-piperidinylsiloxane (Great Lakes Chemicals (Great) Examples include Uvasil (registered trademark) 299, MW=1100-2500 from Lakes Chemical; copolymers of α-methylstyrene-N-(2,2,6,6-tetramethyl-4-piperidinyl)maleimide and N-stearylmaleimide; and 2,4,8,10-tetraoxaspiro[5.5]undecane-3,9-diethanoltetramethylpolymer having 1,2,3,4-butanetetracarboxylic acid. Further suitable high molecular weight hindered amines are described in U.S. Patent No. 5,679,733 by Malik et al. and U.S. Patent No. 6,414,155 by Sassi et al., which are incorporated herein by reference in their entirety for all purposes.

[0074]

[0069] In addition to high molecular weight hindered amines, low molecular weight hindered amines may also be used in the composition. Such hindered amines generally have monomeric properties and have a molecular weight of about 1000 or less, with a molecular weight of about 155 to about 800 in some embodiments and about 300 to about 800 in some embodiments.

[0075]

[0070] Specific examples of such low molecular weight hindered amines include, for example, bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (Tinuvin® 770, MW=481 from Ciba Specialty Chemicals); bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-(3,5-ditert.butyl-4-hydroxybenzyl)butyl-propanediate; bis(1,2,2,6,6-pentamethyl) sebacate -4-piperidinyl); 8-acetyl-3-dodecyl-7,7,9,9-tetramethyl-1,3,8-triazaspiro-(4,5)-decane-2,4-dione, butanediate-bis(2,2,6,6-tetramethyl-4-piperidinyl) ester; tetrakis-(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate; 7-oxa-3,20-diazadispiro(5.1.11.2)heneycosan-20-propanoic acid , 2,2,4,4-tetramethyl-21-oxo,dodecyl ester; N-(2,2,6,6-tetramethyl-4-piperidinyl)-N'-amino-oxamide; ot-amyl-o-(1,2,2,6,6-pentamethyl-4-piperidinyl) monoperoxycarbonate; β-alanine, N-(2,2,6,6-tetramethyl-4-piperidinyl),dodecyl ester; ethanediamide, N-(1-acetyl-2,2,6,6-tetramethylpiperidinyl) -N'-dodecyl; 3-dodecyl-1-(2,2,6,6-tetramethyl-4-piperidinyl)-pyrroridine-2,5-dione; 3-dodecyl-1-(1,2,2,6,6-pentamethyl-4-piperidinyl)-pyrroridine-2,5-dione; 3-dodecyl-1-(1-acetyl,2,2,6,6-tetramethyl-4-piperidinyl)-pyrroridine-2,5-dione (Sanduvar (registered trademark) 3058 from Clariant, MW=448).7); Examples include 4-benzoyloxy-2,2,6,6-tetramethylpiperidine; 1-[2-(3,5-di-tert-butyl-4-hydroxyphenylpropionyloxy)ethyl]-4-(3,5-di-tert-butyl-4-hydroxyphenylpropionyloxy)-2,2,6,6-tetramethyl-piperidine; 2-methyl-2-(2,2,6,6”-tetramethyl-4”-piperidinylamino)-N-(2',2',6',6'-tetramethyl-4'-piperidinyl)propionylamide; 1,2-bis(3,3,5,5-tetramethyl-2-oxopiperazinyl)ethane; 4-oleoyloxy-2,2,6,6-tetramethylpiperidine; and combinations thereof. Other suitable low molecular weight hindered amines are described in U.S. Patent No. 5,679,733 by Malik et al.

[0076]

[0071] Hindered amines can be used alone or in combination in any amount necessary to achieve the desired properties, but typically hindered amines constitute about 0.01 wt.% to about 4 wt.% of the polymer composition.

[0077]

[0072] UV absorbers, such as benzotriazole or benzophenones, may be used in the composition to absorb ultraviolet light energy.Suitable benzotriazoles include, for example, 2-(2-hydroxyphenyl)benzotriazole, for example, 2-(2-hydroxy-5-methylphenyl)benzotriazole; 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole (Cyasolv® UV5411 from Cytec); 2-(2-hydroxy-3,5-di-tert-butylphenyl)-5-chlorobenzotriazole; 2-(2-hydroxy-3-tert-butyl-5-methylphenyl)-5-chlorobenzotriazole; 2-(2-hydroxy Xy-3,5-dicumylphenyl)benzotriazole; 2,2'-methylenebis(4-tert-octyl-6-benzo-triazolylphenol); polyethylene glycol ester of 2-(2-hydroxy-3-tert-butyl-5-carboxyphenyl)benzotriazole; 2-[2-hydroxy-3-(2-acryloyloxyethyl)-5-methylphenyl]benzotriazole; 2-[2-hydroxy-3-(2-methacryloyloxyethyl)-5-tert-butylphenyl]benzotriazole; 2-[2-hydroxy- 3-(2-methacryloyloxyethyl)-5-tert-octylphenyl]benzotriazole; 2-[2-hydroxy-3-(2-methacryloyloxyethyl)-5-tert-butylphenyl]-5-chlorobenzotriazole; 2-[2-hydroxy-5-(2-methacryloyloxyethyl)phenyl]benzotriazole; 2-[2-hydroxy-3-tert-butyl-5-(2-methacryloyloxyethyl)phenyl]benzotriazole; 2-[2-hydroxy-3-tert-amyl-5-(2-methacryloyloxyethyl) Examples include 2-[2-hydroxy-3-tert-butyl-5-(3-methacryloyloxypropyl)phenyl]-5-chlorobenzotriazole; 2-[2-hydroxy-4-(2-methacryloyloxymethyl)phenyl]benzotriazole; 2-[2-hydroxy-4-(3-methacryloyloxy-2-hydroxypropyl)phenyl]benzotriazole; 2-[2-hydroxy-4-(3-methacryloyloxypropyl)phenyl]benzotriazole; and combinations thereof.

[0078]

[0073] Similarly, exemplary benzophenone light stabilizers include 2-hydroxy-4-dodecyloxybenzophenone; 2,4-dihydroxybenzophenone; 2-(4-benzoyl-3-hydroxyphenoxy)ethyl acrylate (Cyasolve® UV209 from Cytec); 2-hydroxy-4-n-octyloxy)benzophenone (Cyasolve® 531 from Cytec); 2,2'-dihydroxy-4-(octyloxy)benzophenone (Cyasolve® UV314 from Cytec); hexadecyl-3,5-bis-tert-butyl Examples include 4-hydroxybenzoate (Cytec's Cyasolve® UV2908); 2,2'-thiobis(4-tert-octylphenolate)-n-butylamine nickel(II) (Cytec's Cyasolve® UV1084); 3,5-di-tert-butyl-4-hydroxycinnamic acid, (2,4-di-tert-butylphenyl) ester (Cytec's Cyasolve® 712); 4,4'-dimethoxy-2,2'-dihydroxybenzophenone (Cytec's Cyasolve® UV12); and combinations thereof.

[0079]

[0074] If used, the UV absorber may constitute about 0.01 wt.% to about 4 wt.% of the total polymer composition.

[0075] Once the polymer composition is formed, it can be molded into parts shaped for use in a wide variety of different applications. For example, the molded parts can be formed using an injection molding process in which dried and preheated plastic granules can be injected into a mold.

[0080]

[0076] Polymer compositions and / or molded parts can be used in a variety of applications. For example, molded parts can be used in lighting assemblies, battery systems, sensors and electronic components, portable electronic devices such as smartphones, MP3 players, mobile phones, computers, televisions, and automotive parts. In one particular embodiment, molded parts can be used in camera modules, such as those commonly used in wireless communication devices (e.g., mobile phones). For example, a camera module may consist of a base, a carrier assembly mounted on the base, a cover mounted on the carrier assembly, etc. The base may have a thickness of about 500 micrometers or less, and in some embodiments may have a thickness of about 10 to about 450 micrometers, and in some embodiments about 20 to about 400 micrometers. Similarly, the carrier assembly may have a wall thickness of about 500 micrometers or less, and in some embodiments may have a wall thickness of about 10 to about 450 micrometers, and in some embodiments about 20 to about 400 micrometers.

[0081]

[0077] In one embodiment, the polymer compositions of the present disclosure can be used to produce housings for electronic devices. For example, the polymer composition may be a housing for a sensor. In one particular embodiment, the sensor may be part of an advanced driver assistance system.

[0082]

[0078] As described above, polymer articles made according to this disclosure are particularly well suited for use in applications where laser transmission welding is utilized. Polymer articles made according to this disclosure have, for example, high transmission properties at the wavelength in which the laser operates. For example, during laser welding, a laser beam can pass through a molded article made according to this disclosure and come into contact with adjacent surfaces to form a weld. The laser beam causes a localized temperature rise at the adjacent surfaces, thereby causing polymer melting and resulting in the formation of a weld. Among the particular advantages, in addition to being laser-transmissive, molded articles made according to this disclosure also have excellent mechanical properties. Any and all types of laser beams can be used during the laser transmission process. The laser may be, for example, a laser diode.

[0083]

[0079] The laser beam can operate with wavelengths of light that are, for example, greater than about 400 nm, greater than about 600 nm, greater than about 800 nm, and generally less than about 2000 nm, for example less than about 1800 nm.

[0084]

[0080] The disclosure of the present invention can be better understood by referring to the following embodiments. [Examples]

[0085]

[0081] Various different polymer compositions were formulated and tested for laser transmission and tensile strength. Tensile strength was measured at a rate of 5 mm / min according to ISO Test 527-2 / 1A (tensile stress at fracture).

[0086]

[0082] The following sample formulations were tested, and the following results were obtained.

[0087] [Table 1]

[0088]

[0083] The above formulation was molded into a test plaque, and the following results were obtained.

[0089] [Table 2]

[0090]

[0084] These and other modifications and variations of the present invention can be made by those skilled in the art without departing from the essence and scope of the invention as described in more detail in the appended claims. In addition, it will be understood that the various embodiments are interchangeable, either whole or in part. Furthermore, those skilled in the art will understand that the foregoing description is merely an example and is not intended to limit the invention to those further described in such appended claims. The claims of the original application of this application are shown below. (Aspect 1) A laser-transparent composition comprising a polymer composition containing a polyester polymer, The polyester polymer comprises a polybutylene terephthalate polymer, the polymer composition further comprises reinforcing fibers and at least one nucleating agent, the reinforcing fibers present in the polymer composition in an amount of about 5 to about 55% by weight, the at least one nucleating agent comprises a benzoate, a salt of a carboxylic acid, sorbitol, a sodium salt of a phosphorus compound, or a mixture thereof, the polymer composition having at least 40% laser transmittance when measured at a wavelength of 980 nm and a thickness of 1.5 mm, the laser-transmissive composition. (Aspect 2) The laser-permeable composition according to aspect 1, wherein the polymer composition contains a mixture of nucleating agents. (Aspect 3) The laser-permeable composition according to aspect 1 or 2, wherein the polymer composition contains a salt of a benzoate and a carboxylic acid. (Aspect 4) The laser-transmissive composition according to any one of aspects 1 to 3, wherein the polymer composition contains a salt of a carboxylic acid, the carboxylic acid comprises an aliphatic carboxylic acid having a carbon chain length of about 14 to about 50 carbon atoms, and the salt of the carboxylic acid comprises an alkali or alkaline earth metal salt of the carboxylic acid. (Aspect 5) The laser-transmissive composition according to aspect 4, wherein the salt of the carboxylic acid is a sodium salt of the carboxylic acid. (Aspect 6) The laser-permeable composition according to any one of aspects 1 to 5, wherein the polymer composition contains the benzoate, and the benzoate contains sodium benzoate. (Aspect 7) The laser-permeable composition according to any one of aspects 3 to 6, wherein each nucleating agent present in the polymer composition is contained in the composition in an amount greater than about 0.001% by weight and less than about 1.5% by weight, and the salt of the carboxylic acid is present in the composition in a weight ratio of about 4:1 to about 1:1 with respect to the benzoate, for example, in a weight ratio of about 3:1 to about 1.5:1. (Aspect 8) The laser-transmissive composition according to any one of aspects 1 to 7, wherein the polymer composition exhibits at least 45% laser transmittance at a thickness of 1.5 mm and at least 50% laser transmittance at a thickness of 1 mm. (Aspect 9) The laser-penetrating composition according to any one of aspects 1 to 8, wherein the polymer composition exhibits a tensile strength greater than about 75 MPa, for example greater than about 120 MPa, for example greater than about 130 MPa, and generally less than about 400 MPa. (Aspect 10) The laser-permeable composition according to any one of aspects 1 to 9, wherein the polymer composition contains the polybutylene terephthalate polymer in an amount of about 55% to about 90% by weight. (Aspect 11) A laser-transmissive composition according to any one of aspects 1 to 10, further comprising a coloring agent. (Aspect 12) The laser-transparent composition according to aspect 11, wherein the coloring agent comprises a black coloring agent, and the black coloring agent is present in the polymer composition in an amount of about 0.1 to about 0.8% by weight. (Aspect 13) The laser-weldable composition according to any one of aspects 1 to 12, wherein the reinforcing fibers include glass fibers. (Aspect 14) The laser-weldable composition according to any one of aspects 1 to 13, wherein the reinforcing fibers are present in the polymer composition in an amount of about 10% to about 35% by weight. (Aspect 15) A molded article formed from a polymer composition according to any one of aspects 1 to 14. (Aspect 16) An assembly comprising a molded article as described in aspect 16, wherein the molded article is laser-welded to an adjacent part. (Aspect 17) A sensor including a housing, wherein the housing is made from a polymer composition described in any one of aspects 1 to 14. (Aspect 18) An advanced driver assistance system including the sensor described in Aspect 17. (Aspect 19) A method for attaching a polymer article to an adjacent surface, comprising the step of bringing a molded article made from a laser-transparent composition according to any one of aspects 1 to 14 into contact with a laser beam, The method, wherein the laser beam propagates through the molded article and comes into contact with an adjacent surface formed from a laser-weldable polymer composition, causing a localized temperature increase on the adjacent surface to a degree sufficient to weld the adjacent surface to the molded article. [Explanation of symbols]

[0091] 10 First molded part 20 Second molded part 30 Laser Devices

Claims

[Claim 1] A laser-permeable composition comprising a polymer composition containing a polyester polymer, The polyester polymer comprises a polybutylene terephthalate polymer, the polymer composition further comprises reinforcing fibers and at least one nucleating agent, the reinforcing fibers present in the polymer composition in an amount of about 5 to about 55% by weight, the at least one nucleating agent comprises a benzoate, a salt of a carboxylic acid, sorbitol, a sodium salt of a phosphorus compound, or a mixture thereof, the polymer composition having at least 40% laser transmittance when measured at a wavelength of 980 nm and a thickness of 1.5 mm, the laser-transmissive composition.

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