Curable molding compositions based on unsaturated polyesters and containing acid cellulose esters and polystyrene
United States Patent 1 1&#39; Hess et al.  
 1451 Apr. 15, 1975 CURABLE MOLDING COMPOSITIONS BASED ON UNSATURATED POLYESTERS AND CONTAINING ACID CELLULOSE ESTERS AND POLYSTYRENE [75] Inventors: Bernhard Hess, Kapellen-Moers;  
 &#39; Karl Raichle, Krefeld-Bockum, both of Germany; Bayer [73] Assignees: Aktiengesellschaft, Leverkusen,  
  Germany 221 Filed: Sept. 13, 1973 211 App]. No.: 397,142  
 [30] Foreign Application Priority Data Sept. 20, 1972 Germany 2246105 [52] US. Cl. 260/16 [51] Int. C|....; C08g 39/10 [58] Field of Search 260/16 Primary Examiner-Morris Liebman Assistant ExaminerEdward Woodberry Attorney, Agent, or Firm-Connolly and Hutz [57] ABSTRACT The invention relates to moulding compositions based on olefinically unsaturated polyesters, containing acid cellulose esters and polystyrene, which can be cured to give homogeneously coloured mouldings of low shrinkage.  
 10 Claims, No Drawings CURABLE MOLDING COMPOSITIONS BASED ON UNSATURATED POLYESTERS AND CONTAINING ACID CELLULOSE ESTERS AND POLYSTYRENE The invention relates to moulding compositions based on olefinically unsaturated polyesters, containing acid cellulose esters and polystyrene. which can be cured to give homogeneously coloured mouldings of low shrinkage.  
  It is known that the shrinkage of heat-cured compression moulding compositions based on solutions of polyesters containing olefinically unsaturated dicarboxylic acid radicals referred to for brevity as unsaturated polyesters in copolymerisable vinyl monomers can be considerably reduced. and that their surface can be improved. by combination with thermoplastics. Known combinations of this nature are manufactured. for example. by mixing two solutions A and B consisting, on the one hand. of the clear solution of an unsaturated polyester in styrene (solution A) and. on the other hand. the clear solution of a thermoplastic in styrene (solution B). The mixture can be compatible or incompatible; thus. on mixing either a clear solution or a more or less stable dispersion is produced.  
  To manufacture a compression moulding composition. glass fibres, fillers and peroxide. and frequently also chemical thickeners. for example oxides or hydroxides of a metal of group 11 of the periodic system. such as magnesium oxide or calcium oxide or hydroxide. which consolidates the composition through salt formatiomare added to the mixture of the solutions A and B. The compression moulding composition is heatcured to give mouldings.  
  The most streamlined method of manufacture of larger pressings is via thickened resin mats. These are manufactured by impregnating glass fibre mats with the glass-free mixture described. which contains chemical thickeners. especially MgO. and protecting the surfaces of the mats on both sides by covering films. The films prevent the evaporation of the vinyl monomer and permit the mats to be rolled up and hence to be stored in a space-saving way. The expectations from a good resin mat are that it thickens up after not more than days storage at room temperature. that its surface is then almost dry. so that the covering films adhering to both sides can be pulled off without great exertion of force and without damaging the mat, and that the mat can be hot-pressed to give perfect mouldings.  
  As explained below, using the previously known combinations of thermoplastics with solutions of unsaturated polyesters in copolymerisable vinyl monomers it is not possible to manufacture a resin mat having the good properties mentioned. which can be pressed to give mouldings which are perfectly coloured and have been cured with little shrinkage and have a perfect surface.  
  Amongst the thermoplastics which can be considered. the use of cellulose acetobutyrate (C.A.B.) and- /or cellulose acetopropionate (C.A.P.) in combination with highly reactive unsaturated polyesters in copolymerisable vinyl monomers is known from German Offenlegungsschriften (German Published Specifications) 1,694,857 and 1,953,062. Our own comparison experiments have shown that whilst it is possible to manufacture resin mats with a sufficiently dry surface on the basis of neutral or of acidified CAB/CAP in combination with styrene solutions of highly reactive unsaturated polyesters. the cured mouldings manufactured from these mats display. in dark colourations, an unattractive flecked marbled appearance, which is why additional lacquering frequently becomes necessary.  
  Comparison experiments with neutral polystyrene as the thermoplastic (according to DOS 1,694,898) showed the difficulty that the mixture of the solution A unsaturated polyester in styrene with the solution B polystyrene dissolved in monomeric styrene formed a dispersion which soon separated again into two phases and furthermore that the resin mats manufactured therefrom were still tacky after 5 days storage at room temperature, so that the covering films could only be pulled off with difficulty and so as to damage the resin mat. and that the cured mouldings, whilst homogeneously coloured. showed surface blotches and left a deposit in the press.  
  The same difficulties on mixing the solutions A and B and adverse properties of the cured mouldings manifested themselves to an increased extent in comparison experiments with acid polystyrene as the thermoplastic (according to DOS (German Published Specification) 1.953.062) or with styrenemaleic anhydride copolymers (according to US. Pat. No. 3.665.055). except that here the resin mat. as positive feature. showed a dry surface.  
  It has now been found that moulding compositions based on solutions of olefinically unsaturated polyesters in copolymerisable vinyl monomers. which contain a thermoplastic mixture consisting of acid CAB and/or CAP on the one hand and small amounts of neutral and/or acid polystyrene on the other. form a stable dispersion and yield resin mats with dry surfaces which can be pressed to give homogeneously coloured low shrinkage mouldings of perfect surface. This is all the more surprising since comparison experiments with a mixture of thermoplastics. consisting of neutral CAB and neutral polystyrene. do not yield homogeneously coloured mouldings. (Compare Table l).  
  The invention hence relates to moulding compositions which can be cured to give homogeneously coloured mouldings of low shrinkage, and which consist of mixtures of 1. Polyesters containing a,B-unsaturated dicarboxylic acid radicals.  
 2. copolymerisable vinyl monomers,  
 3. Customary polymerization inhibitors. in the customary amounts.  
 4. Customary polymerisation initiators. in the customary amounts.  
 5. Pigments.  
 6. Optionally, chemical thickeners. especially those based on oxides or hydroxides of a metal of group 11,  
 7. Optionally. agents for conferring thixotropy,  
 8. Other customary additives and auxiliaries. characterised in that they contain 9. 5307r of acid cellulose acetobutyrate (CAB) and- /or acid cellulose acetopropionate (CAP). relative to the resin mixture without (5) and (8), and  
 10. 1-157: of polystyrene.  
  The above and subsequent percentage data are percentages by weight.  
  The mixtures according to the invention also differ externally from the previously known combinations of this nature, which are usually manufactured by mixing two clear solutions A and B solution A: unsaturated polyester in styrene; solution B: thermoplastic in styrene in that the solution B is not a clear solution but a dispersion which consists of the mixture of two thermoplastics which are incompatible in styrene. This dispersion in most cases remains stable on further mixing with the solution A and can be converted into mouldings having the optimum properties described.  
  Unsaturated polyesters are the customary polycondensation products of a,B-unsaturated dicarboxylic acids with polyols, especially glycols (compare .1. Bjorksten et al. Polyesters and their Application Reinhold Publishing Corp., New York, 1956). Amongst these, the highly reactive polyesters. that is to say those with as high a content of olefinically unsaturated groups as possible, are preferred, since they yield the products of best quality. Such highly reactive polyesters can be obtained in a manner which is in itself known by using, as glycols, those of as low a molecular weight at possible, such as ethylene glycol or propylene glycol, and condensing these exclusively with a-B-unsaturated dicarboxylic acids or with mixtures of these dicarboxylic acids which contain as little as possible of other dicarboxylic acids which are devoid of olefinically unsaturated groups, such as phthalic acid, tereph- ,thalic acid and aliphatic dicarboxylic acids. The preferred amount of unsaturated polyesters is about 25-50% of the resin mixture without fillers and pigments.  
 C opolymerisable vinyl monomers are the customary vinyl monomers, preferably styrene. nuclearsubstituted styrenes or divinylbenzene, optionally mixed with smaller amounts of acrylic acid or methacrylic acid or their esters, esters of vinyl alcohol or allyl alcohol and the like. The preferred amounts are 40-60% of the resin mixture without fillers and pigments. Acid CAB and CAP are cellulose esters in which at least half the hydroxyl groups of the cellulose which are capable of esterification are esterified with butyric acid or propionic acid, a further part is esterified with acetic acid and the remaining hydroxyl groups of the cellulose are esterified at least partially so as to form an acid half-ester, for example by reaction with an acid anhydride, such as anhydrides of phthalic acid, tetrahydrophthalic acid, trimellitic acid or pyromellitic acid. Cellulose acetobutyrates containing about 17-21% of acetic acid and about 45-50% of butyric acid, which possess acid numbers of about 10 to 80, are particularly suitable.  
  Of course, acid groups can also be introduced into the cellulose through other chemical reactions, for example by reaction with chloroacetic acid. The reaction with the acid anhydrides can be carried out in styrene solutions at an elevated temperature, the polymerisation of the sytrene being prevented by adding a sufficiently large amount of inhibitors. However, the reaction can also be carried out in inert solvents though these have to be removed again.  
  The acid CAB and/or CAP can be employed in amounts of about 5-307: of the resin mixture without filler and pigments, preferably in amounts of -20%.  
  Suitable polystyrenes are: the customary homopolymers of styrene with molecular weights of 5,000 to 10,000,000, but preferably those with molecular weights of about 20,000 to 300,000, and also copolymers of styrene with small amounts of one or more monomers such as a-methylstyrene, vinyltoluene, tert.-  
 butylstyrene, chlorostyrene, butadiene, acrylic or methacrylic acid, their esters or amides, hydroxypropyl methylacrylate, acrylamide, B-methacryloxyethylsulphonic acid or -phosphoric acid, or neutral or acid esters of maleic acid or fumaric acid.  
  Through the comonomers described, the copolymer can contain functional groups. These can be present in amounts&#39;of 0.02-2 mequivalent/g, preferably 0.05-l.0 mequivalent/g.  
  Polystyrenes which have been manufactured in the presence of the acid or neutral CAB or CAP in styrene solution are particularly advantageous since this procedure results in particularly stable and fine dispersions.  
  Frequently, an amount of polystyrene of 2% relative to the resin mixture without fillers and pigments suffices, but larger amounts, up to 15%, can also be of advantage.  
  The mixtures according to the invention contain customary inhibitors which prevent a premature uncontrolled gelling such as: hydroquinone, toluhydroquinone, p-benzoquinone, p-tert.-butylpyrocatechol, chloranil, naphthoquinone, copper compounds, pnitrosodimethylaniline and the like.  
  Customary radical-forming initiators are added thereto, such as benzoyl peroxide. tert.-butyl perbenzoate, tert.-buty| peroxide, cyclohexanone peroxide, tert.-butyl peroctoate and azoisobutyrodinitrile.  
  Known chemical thickeners are the oxides and hy droxides of the metals of group ll, preferably the oxides and hydroxides of magnesium and calcium, optionally in conjunction with small amounts of water.  
  Suitable pigments and dyestuffs are the customary pigments and dyestuffs which do not interfere with the polymerisation, and can be organic or inorganic co- Ioured pigments, such as iron oxide in various colour shades, chromium oxide. cadmium sulphite or phthalocyanines, usually in combination with white pigments such as titanium dioxide, zinc oxide or lithopone.  
  Agents for conferring thixotropy are the usual ones, which may be inorganic, such as Aerosil, or organic, which contain acid amide or urethane groups, or cyclohexylamides of higher fatty acids (compare DAS (German Published Specification) 1,182,816 and 1,217,611, and BE 693,580).  
  Other customary additives and auxiliaries are inert inorganic fillers such as calcium carbonate, silicates, aluminas, chalk, carbon, reinforcing fibres such as glass fibres, also in the form of fabrics or mats, synthetic organic fibres, cotton, asbestos or metals, lubricants and release agents, such as zinc stearate, and UV- absorbers.  
  To manufacture the moulding compositions according to the invention, fillers, chemical thickeners, pigments, initiators and glass fibres can be mixed into the resin mixture, consisting of the solutions A and B, in a kneader or a mortar in the case of hand experiments or glass fibre mats or fabrics can be impregnated with the composition which is free of glass fibres and left to ripen for 5 days at room temperature, whilst preventing major amounts of the vinyl monomer from evaporating, through suitable measures (for example sealed containers and covering films). The moulding compositions thickened according to the invention have a dry, non-tacky surface and can be heat-cured to give homogeneously coloured low shrinkage mouldings having perfect glossy surfaces.  
  The examples and comparison examples which follow explain the invention.  
 EXAMPLES 40C, is stirred the solution. which is also clear, of the polystyrene dissolved in styrene, Part II, whereby a fine dispersion is produced which represents solution B. In the case of the comparison solutions without phthalic Parts denote parts by weight. and viscosity data are 5 anhydride. the 3 hours warming to I C is omitted. measurements in the Hoppler falling ball viscometer.  
  Manufacture of the Mixtures of Solutions A and B Manufacture of Solution A 60 parts of solution A are mixed with 40 parts of solusoluuon A the lf 9 0 8 unsaturated tion B at room temperature. The mixture according to polyesterame composltlon OfwhlCh 1S given below- The 10 the invention of solutions A and B I is a stable disperpolyester manuffl&#39;ctlffed In -k manner y melt sion (Example I), and the comparison mixtures are in condensano&#34; a ls-dlssolved I yf glve 11 65% part clear solutions and in part dispersions of varying strength solut1on. Before dissolving it, toluhydro- Stabmty (Examples 13 to 1d). qumone added- I g The properties of the mixtures and those of the moulding compositions manufactured therefrom and of the cured mouldings are summarised in Table I.  
 Maleic anhydride 932 g Manufacture of Moulding Compositions Phthalic anhydride 74 g l.2-Propylene it-col 853 g The ease of colouratlon of moulding COITIPOSIIZIOIIS IS Toluhydmquimns g assessed in relation to a cured red-brown resin compo- Characteristic data of the styrene solution: Sition. Solids content 65% Viscosity (20C 3300 CP I00 parts of the mixture of solutions A and B accord- Acid &#34;umber l7 ing to the invention and 100 parts of the comparison mixtures of solutions A and B are intimately mixed with the additives listed below, and 66 parts of a glass fibre mat are impregnated with the composition and pro- Manufacture of Solution B tected on both sides with covering films. After 5 days F m l l l d t h storage at room temperature the covering films are f Z T Q g S pulled off and portions of 125 parts of the thickened-up Ce Z ZP G erefl g 3 resin mat are pressed for 5 minutes at 145C under 120 as d wasAuSse w 10 a a viscosity 0 k /cm to give sheets (I2 X 12 cm) having a diagonal decor mg T 871-56 f comamed rib and a nap. The pressings all show the known low 18% of Gene 45% of butync acld&#39; had shrinkage in comparison to moulding compositions free OH numb? of of thermoplastic. The properties of the resin mats and C ompositlon of the solut on B l according to the mof the cured mouldings are listed in Table 1 vention. and of the comparison solutions B 2 to B 5, in parts by weight:  
 100.0 parts of a mixture of solutions A and B 80.0 parts of calcium carbonate 40 L5 parts of MgO 4.0 parts of zinc stearate sllumni B l B 2 B 3 B 4 B 5 L65 parts of black iron oxide 3.35 parts of red iron oxide CAB l I20 I20 I20 I20 0.75 part of tcrL-butyl perbenzoatc Styrene. Part I I80 I80 I80 I80 I80 0.4 part of water Phthulic anhydride I3 I3 &#39;I&#39;oluhydroquinonc 0.1 0.1 (H 0.] 0| 66.00 parts of glass fibre mat Table I Example/ Solution Viscosity of Thermoplastic Mixture Resin Colouration Surface Comparison A B Solution A B Solution A B mat of the of the Moulding Moulding No. I A B I 4,000 cP Acid CAB I cloudy/stable dry homogeneous gloss polystyrene I No. I a A B 2 4,500 c? CAB I clear/stable dry inhomo gloss geneous No. I b A B 3 4.300 c? Acid CAB I clear/stable dry inhomogloss geneous No. l c A B 4 1,500 cP Polystyrene I cloudy/ tacky homogeneous blotches unstable No. I d A B 5 4,000 c? CAB I cloudy/stable dry inhomogloss polystyrene I geneous Polystyrene (molc- 40 I 40 EXAMPLE 2 cular weight 70.000) F ll I00 I00 100 I00 I00 Manufacture of Solution B6 according to the Invention: The CAB I and toluhydroqumone are dISSOlVCl in styrene, Part I, at C, phthalic anhydride is then added, and the solution is warmed to C and kept at 1 10C for 3 hours. Into the clear solution, cooled to Toluhydroquinone The CAB l, phthalic anhydride. and toluhydroquinone are dissolved in styrene at 80C and the solution is warmed to 110C. After approx. 1 hour. the clear solution becomes cloudy and after a further 2 hours at 1 C the solution is cooled to room temperature. Approx. 40 parts of polystyrene have formed. as found by determining the solids content.  
  60 parts of the solution A are mixed with 40 parts of the solution B6. The viscosity of the mixture is 5.700 cP. The mixture is a stable dispersion which can be converted to give a resin mat corresponding to the formulation described above and having a dry surface: after 5 days storage at room temperature this mat can be cured to give homogeneously coloured mouldings of low shrinkage and fault-free surface.  
 What we claim is:  
  l. A curable moulding composition comprising -50% by weight of an unsaturated polyester of an a,B-unsaturated dicarboxylic acid and a polyol; 40-60% by weight of a copolymerizable vinyl monomer; a polymerization inhibitor; a pigment; a polymerization initiator; 5-30% by weight of an acid cellulose ester selected from the group consisting of acid cellulose acetobutyrate and acid cellulose acetopropionate, each said acid cellulose containing carboxylic acid groups. and 1-l57( by weight of polystyrene. said percentages by weight being based on the total weight of the composition minus the weight of said pigment.  
  2. The composition of claim 1 wherein said at least one acid cellulose ester is present in an amount of 8 10-20% by weight.  
  3. The composition of claim I wherein said polystyrene has been produced in the presence of said at least one acid cellulose ester in a styrene solution.  
  4. The composition of claim 1 wherein said polystyrene has a molecular weight of 5,000 to 10,000,000.  
  5. The composition of claim 1 wherein said polystyrene is a copolymer of styrene and a minor amount of at least one monomer selected from the group consisting of a-methylstyrene. vinyltoluene, tert.-butylstyrene, chlorostyrene, butadiene, acrylic acid, methacrylic acid, the esters and amides of said acids, hydroxypropylmethacrylate, B-methacryloxyethylsulfonic acid, B-methacryloxyphosphoric acid and the neutral and acid esters of maleic and fumaric acids.  
  6. The composition of claim 1 wherein said at least one acid cellulose ester is acetobutyrate containing 17-21% of acetic acid and 45-50% of butyric acid and having an acid number of 10-80.  
  7. The composition of claim 1 including a chemical thickener which is an oxide or a hydroxide of a metal of Group 11 of the Periodic System.  
  8. The composition of claim 1 which includes an inert filler.  
  9. The method of producing a hardened composition which comprises curing the composition of claim 1.  
 10. The hardened composition produced by the method of claim 9.  
 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3 7 137 DATED 1 April 15, 1975 INVENTOR(S) Bernhard Hess et 8.1  
  It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:  
  The title page, left hand column, the last line of [75] should read of Germany and the first line of [73] should read Assignees: Bayer Aktiengesellschaft, Leverkusen, 0 Signed and Scaled this seventh Of Oct0&#39;ber1975 [SEAL] Attest: Q  
 RUTH C. MASON c. MARSHALL DANN Arresting Officer Commissioner oflatenls and Trademarks