JP5153632B2 - 高弾性ポリオレフィンファイバーを含む複合材料と、それを製造する方法 - Google Patents
高弾性ポリオレフィンファイバーを含む複合材料と、それを製造する方法 Download PDFInfo
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- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2223/00—Use of polyalkenes or derivatives thereof as reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2223/00—Use of polyalkenes or derivatives thereof as reinforcement
- B29K2223/10—Polymers of propylene
- B29K2223/12—PP, i.e. polypropylene
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- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
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- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/18—Fabrics, textiles
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- B32B2310/00—Treatment by energy or chemical effects
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- B32B38/00—Ancillary operations in connection with laminating processes
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Description
複合材料は、各構成要素の望ましくない特徴を最小にしながら、望ましい特徴を維持した製品を得るために、多くの分野において発展してきた。例えばグラスファイバーは、優れた引っ張り強さの特徴を示すが、誘電率が約6である。そのため、高い使用率での電気的な用途にはたいてい適さない。しかしながら、グラスファイバーは、例えば、望ましい電気的特性を示すある種のフルオロカーボン樹脂などの樹脂と組み合わせて、物理的特性のみならず良好な電気的特性を有する複合材料を形成することができる。
本発明は、多層(multi-layer)の複合構造体、その構造体を製造する方法、及びその構造体を使用する方法を対象にしている。ある実施形態では、開示された構造体は、約8GPaより大きく他の実施形態ではさらに高い係数(modulus)と、約100μm未満の最大断面寸法とを有する半結晶性(semi-crystalline)ポリオレフィンファイバーを含んだ第1層を含むことができる。また、ある実施形態では、ポリオレフィンファイバーは、例えば約400MPaを越えるような高い引っ張り強さを示し、例えば約1.3g/cm3未満の低い密度を有している。また、複合構造体は、第1層と同じ又は異なる第2層と、それらの層を互いに固定するためのポリマー性接着剤とを含むこともできる。ある実施形態では、ポリオレフィンはポリプロピレンである。ある特定の実施形態では、ポリオレフィンファイバーは溶融押出プロセス、例えば少なくとも約6の延伸比での引き延ばしを含む溶融押出プロセスで、形成することができる。
GLA グラスファイバー布地であり、Fiberglast Company社の製品番号245-Cで入手可能である。
CAR カーボンファイバー布地であり、Defender Industries社の製品番号751434で入手可能である。
PP 低弾性ポリプロピレン織布であり、Defender Industries社の製品番号751422で入手可能である。
PET ポリエチレンテレフタレートファイバー織布であり、Defender Industries社の製品番号751425で入手可能である。
KEV ケブラー(登録商標)布地であり、Defender Industries社の製品番号751429で入手可能である。
HMPP 上述の高弾性ポリプロピレンヤーンの織布である。
Claims (17)
- (i)8GPaより大きい弾性率と100ミクロン未満の最大断面寸法と、少なくとも、広角X線散乱(WAXS)測定技術に従って測定された80%より大きい結晶化度と;小角X線散乱(SAXS)測定技術に従って測定された1より大きい子午線強度に対する赤道強度の比とのうちいずれか一方の特徴とを有する複数の溶融押出し半結晶性ポリプロピレンファイバー(a)と、
ポリマー性接着剤と結合可能な表面の官能基又は表面構造と、
を有する第1布地層と、
(ii)第2布地層と、
(iii)前記第1布地層(i)と前記第2布地層(ii)とを固定するポリマー性接着剤と、
を含む多層複合構造体。 - 前記第1布地層(i)が、織り合わされたパターンの中に、第2のファイバー(b)と共にポリプロピレンファイバー(a)を含む織布であることを特徴とする請求項1に記載の多層複合構造体。
- 前記第2布地層(ii)が、ポリマーマトリクス中又は金属中に第3のファイバー(c)を含むことを特徴とする請求項1に記載の多層複合構造体。
- 前記接着剤(iii)が、前記ポリプロピレンファイバー(a)より低融点の熱可塑性材料と熱硬化性樹脂とから選択されることを特徴とする請求項1に記載の多層複合構造体。
- 前記ファイバー(a)が、溶融押出しポリプロピレンフィルムに付着している半分分離されたマクロファイバー又はミクロファイバーを含むことを特徴とする請求項1に記載の多層複合構造体。
- 1.5g/cm3未満の密度と80MPaより大きい曲げ強度を有することを特徴とする請求項1に記載の多層複合構造体。
- 1.2g/cm3未満の密度と3GPaより大きい曲げ弾性率を有することを特徴とする請求項1に記載の多層複合構造体。
- 3.5未満の誘電率を有することを特徴とする請求項1に記載の多層複合構造体。
- (i)10GPaより大きい弾性率と100ミクロン未満の最大断面寸法と、少なくとも、広角X線散乱(WAXS)測定技術に従って測定された80%より大きい結晶化度と;小角X線散乱(SAXS)測定技術に従って測定された1より大きい子午線強度に対する赤道強度の比とのうちいずれか一方の特徴とを有する複数の溶融押出し半結晶性ポリプロピレンファイバー(a1)を有する第1布地層と、
(ii)第2布地層と、
(iii)前記第1布地層(i)と前記第2布地層(ii)とを固定するポリマー性接着剤と、
を含む多層複合構造体。 - 前記第2布地層(ii)が、前記第1布地層(i)の全体にわたって不連続であることを特徴とする請求項9に記載の多層複合構造体。
- 前記第2布地層(ii)が、ポリマーマトリクス中に第3のファイバーを含む不織布であることを特徴とする請求項9に記載の多層複合構造体。
- 1.5g/cm3未満の平均密度、100MPaより大きい曲げ強度、及び10GPaより大きい曲げ弾性率を有することを特徴とする請求項9に記載の多層複合構造体。
- 3.0未満の誘電率を有することを特徴とする請求項9に記載の多層複合構造体。
- 回路基板、レドーム、保護用収容体、及び車両部品から選択された物品を製造するための請求項1乃至13のいずれか1項に記載の多層複合構造体の使用。
- 1.5g/cm3未満の平均密度を有するラミネート構造体であって、
(a)20GPaより大きい弾性率と100ミクロン未満の最大断面寸法と、少なくとも、広角X線散乱(WAXS)測定技術に従って測定された80%より大きい結晶化度と;小角X線散乱(SAXS)測定技術に従って測定された1より大きい子午線強度に対する赤道強度の比とのうちいずれか一方の特徴とを有するファイバーを含む第1及び第2の外側層と、
(b)複数の内側層であって、そのうち少なくとも1つ以上の前記内側層が、少なくとも8GPaの弾性率、400MPaより大きい引っ張り強さ、及び1.3g/cm3未満の密度を有する複数の溶融押出しファイバーを含む織布である前記複数の内側層と、
(c)前記ラミネート構造体の少なくとも2つの層を互いに接着する接着剤と、
を含むことを特徴とするラミネート構造体。 - 前記外側層が、ファイバーガラスの布地であることを特徴とする請求項15に記載のラミネート構造体。
- 回路基板、レドーム又は車両部品であることを特徴とする請求項15に記載のラミネート構造体。
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/205,662 US7892633B2 (en) | 2005-08-17 | 2005-08-17 | Low dielectric composite materials including high modulus polyolefin fibers |
US11/205,661 | 2005-08-17 | ||
US11/205,575 US8057887B2 (en) | 2005-08-17 | 2005-08-17 | Composite materials including high modulus polyolefin fibers |
US11/205,661 US7648607B2 (en) | 2005-08-17 | 2005-08-17 | Methods of forming composite materials including high modulus polyolefin fibers |
US11/205,662 | 2005-08-17 | ||
US11/205,575 | 2005-08-17 | ||
PCT/US2006/030557 WO2007021611A1 (en) | 2005-08-17 | 2006-08-03 | Composite materials including high modulus polyolefin fibers and method of making same |
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JP2009504455A JP2009504455A (ja) | 2009-02-05 |
JP2009504455A5 JP2009504455A5 (ja) | 2009-05-28 |
JP5153632B2 true JP5153632B2 (ja) | 2013-02-27 |
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JP2008526980A Active JP5153632B2 (ja) | 2005-08-17 | 2006-08-03 | 高弾性ポリオレフィンファイバーを含む複合材料と、それを製造する方法 |
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EP (1) | EP1915476B1 (ja) |
JP (1) | JP5153632B2 (ja) |
AU (1) | AU2006280176B2 (ja) |
BR (1) | BRPI0615205B1 (ja) |
CA (1) | CA2619172C (ja) |
EA (1) | EA016944B1 (ja) |
ES (1) | ES2621124T3 (ja) |
WO (1) | WO2007021611A1 (ja) |
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CA2619172A1 (en) | 2007-02-22 |
EP1915476B1 (en) | 2017-01-04 |
AU2006280176A1 (en) | 2007-02-22 |
EA016944B1 (ru) | 2012-08-30 |
EP1915476A4 (en) | 2011-03-09 |
AU2006280176B2 (en) | 2011-11-24 |
EA200800603A1 (ru) | 2008-08-29 |
CA2619172C (en) | 2013-07-16 |
ES2621124T3 (es) | 2017-07-03 |
BRPI0615205A2 (pt) | 2013-01-08 |
WO2007021611A1 (en) | 2007-02-22 |
BRPI0615205B1 (pt) | 2017-07-04 |
EP1915476A1 (en) | 2008-04-30 |
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