Thermoplastic Product and Method for the Production of a Composite Product

Abstract

A composite thermoplastic product includes a first polar engineering thermoplastic cohesively bonded to a second thermoplastic. The first thermoplastic can contain a polar thermoplastic polymer cohesively bonded to the second thermoplastic. The second thermoplastic can contain a styrene-based thermoplastic elastomer and a polyolefin. Methods for the production of the composite product include methods for forming an adhesive bond between polar engineering thermoplastics such as ABS, ABS/PC, PC or PMMA and non-polar thermoplastic elastomers containing styrene elastomers, such as SEBS or SEPS, combined with a polyolefin polymer.

1 . A thermoplastic product, comprising: a first polar engineering thermoplastic cohesively bonded to a second thermoplastic, the second thermoplastic comprising a styrene-based thermoplastic elastomer and a polyolefin. 
   
   
       2 . The thermoplastic product of  claim 1 , wherein a crystalline portion of the styrene-based thermoplastic elastomer constitutes not more than 20% by weight of the styrene-based thermoplastic elastomer. 
   
   
       3 . The thermoplastic product of  claim 1 , wherein the first polar engineering thermoplastic comprises a material selected from the group consisting of: ABS (acrylonitrile butadiene styrene copolymers), ABS/PC (acrylonitrile butadiene styrene copolymers/polycarbonate), PC (polycarbonate) and PMMA (polymethylmethacrylate). 
   
   
       4 . The thermoplastic product of  claim 1 , wherein the second thermoplastic comprises a material selected from the group consisting of: SEBS and SEPS. 
   
   
       5 . The thermoplastic product of  claim 1 , wherein the second thermoplastic comprises a material selected from the group consisting of: a SEBS in which the side chain represents a fraction of more than 60% and a SEPS with amorphous soft segments. 
   
   
       6 . The thermoplastic product of  claim 1 , wherein the second thermoplastic comprises a material selected from the group consisting of: an acid-modified polypropylene and an acid-modified styrene-based thermoplastic elastomer. 
   
   
       7 . The thermoplastic product of  claim 1 , wherein the polyolefin comprises a polymer selected from the group consisting of: an atactic polypropylene and an α-olefin. 
   
   
       8 . The thermoplastic product of  claim 1 , wherein the polyolefin comprises a polymer selected from the group consisting of: a homopolymer of polyethylene, a copolymer of polyethylene, a homopolymer of polypropylene and a copolymer of polypropylene. 
   
   
       9 . The thermoplastic product of  claim 1 , wherein the second thermoplastic is cohesively bonded to the first polar engineering thermoplastic with peeling force of at least about 32 MPa. 
   
   
       10 . The thermoplastic product of  claim 1 , further comprising an electroplating layer contacting the first polar engineering thermoplastic. 
   
   
       11 . The thermoplastic product of  claim 1 , wherein
 a. the first polar engineering thermoplastic comprises a material selected from the group consisting of: ABS (acrylonitrile butadiene styrene copolymers), ABS/PC (acrylonitrile butadiene styrene copolymers/polycarbonate), PC (polycarbonate) and PMMA (polymethylmethacrylate);   b. the styrene-based thermoplastic elastomer comprises at least one material selected from the group consisting of: a SEBS in which the side chain represents a fraction of more than 60%, a SEPS with amorphous soft segments and an acid-modified styrene-based thermoplastic elastomer; and the styrene-based thermoplastic elastomer has a crystalline portion that constitutes not more than 20% by weight of the styrene-based thermoplastic elastomer; and   c. the polyolefin comprises a polymer selected from the group consisting of: an atactic polypropylene, an α-olefin and an acid-modified polypropylene; and   d. the thermoplastic product further comprises a material selected from the group consisting of: calcium carbonate, talc, barium sulphate, metal oxides, metal hydroxides, and silicic acid.   
   
   
       12 . A method for producing a composite product, the method comprising
 a. providing an injection mold,   b. injection molding the composite product in the injection mold, the composite product including a hard plastic part and a soft plastic part comprising a styrene-based elastomer and a polyolefin; and   c. selectively electroplating the composite product.   
   
   
       13 . The method of  claim 12 , wherein injection molding the composite product includes injection molding a polar amorphous engineering thermoplastic in the hard plastic part. 
   
   
       14 . The method of  claim 12 , wherein injection molding the composite product includes injection molding an acrylonitrile butadiene styrene copolymer in the hard plastic part. 
   
   
       15 . The method of  claim 12 , wherein injection molding the composite product includes injection molding a styrene-based elastomer having a crystalline portion of not more than 20% by weight of the elastomer in the soft plastic part. 
   
   
       16 . The method of  claim 12 , wherein injection molding the composite product includes injection molding the soft plastic part comprising a polystyrene poly(ethylene/butylene) polystyrene that has a side chain fraction of more than 60%. 
   
   
       17 . The method of  claim 12 , further comprising overmolding the hard plastic part with the thermoplastic made from the styrene-based elastomer and the polyolefin. 
   
   
       18 . The method of  claim 12 , further comprising performing a reject inspection after the injection and the selective electroplating. 
   
   
       19 . The method of  claim 12 , further comprising one or more steps selected from the group consisting of: selectively electroplating a surface of the hard plastic part, incorporating metallic effect spangles in the composite product, and hardening the composite product and applying printing to the hardened composite product. 
   
   
       20 . The method of  claim 12 , wherein injection molding the composite product includes injection molding a polar amorphous engineering thermoplastic in the hard plastic part and injection molding a styrene-based elastomer having a crystalline portion of not more than 20% by weight of the elastomer in the soft plastic part; and the method further comprises:
 a. overmolding the hard plastic part with the styrene-based elastomer and the polyolefin;   b. performing a reject inspection after the injection and the selective electroplating;   c. hardening the composite product; and   d. applying printing to the hardened composite product