WO2013046434A1 - ベンゾオキサジン樹脂組成物及び繊維強化複合材料 - Google Patents
ベンゾオキサジン樹脂組成物及び繊維強化複合材料 Download PDFInfo
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C08L61/04, C08L61/18 and C08L61/20
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- C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
- C08G73/02—Polyamines
- C08G73/0233—Polyamines derived from (poly)oxazolines, (poly)oxazines or having pendant acyl groups
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
- C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0025—Crosslinking or vulcanising agents; including accelerators
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/34—Heterocyclic compounds having nitrogen in the ring
- C08K5/35—Heterocyclic compounds having nitrogen in the ring having also oxygen in the ring
- C08K5/357—Six-membered rings
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- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
- C08L77/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof
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- C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
- C08L79/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08L79/06—Polyhydrazides; Polytriazoles; Polyamino-triazoles; Polyoxadiazoles
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- C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2377/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
- C08J2377/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2463/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2477/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
- C08J2477/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/254—Polymeric or resinous material
Definitions
- the present invention is a benzoxazine resin composition that can achieve various excellent mechanical properties necessary for aircraft applications in a high dimension, aircraft applications, marine applications, automobile applications, sports applications using the resin compositions,
- the present invention relates to a fiber reinforced composite material that is suitable for general industrial use and that can be further reduced in weight because various excellent mechanical properties can be obtained simultaneously in a high dimension, and a prepreg that can be used to obtain the composite material.
- Fiber reinforced composite materials composed of various fibers and matrix resins are widely used for aircraft, ships, automobiles, sporting goods and other general industrial applications because of their excellent mechanical properties.
- the application range of fiber reinforced composite materials has been expanded as the use results have been increased.
- those using a compound having a benzoxazine ring have been proposed in Patent Documents 1 and 2, for example.
- the compound having a benzoxazine ring has excellent moisture resistance and heat resistance, but has a problem of inferior toughness, and has been devised to compensate for the defects by blending epoxy resin and various resin fine particles.
- CAI compressive strength after impact
- ILSS interlaminar shear strength at high temperature and high humidity
- bending fracture toughness etc.
- Patent Document 3 discloses a technique of blending polyamide 12 fine particles with a thermosetting resin such as an epoxy resin for the purpose of improving CAI.
- a fiber reinforced composite material using such a technique can maintain CAI to some extent high, but has not yet achieved both ILSS at high temperature and high humidity. Therefore, when a composite material currently used is replaced, development of a material having higher mechanical properties at the same time is required in order to reduce the weight as compared with the current situation.
- An object of the present invention is to provide a fiber reinforced composite material capable of simultaneously achieving excellent CAI, ILSS and bending fracture toughness in a high dimension and maintaining a high glass transition temperature of the resin material, and a prepreg and benzoxazine resin composition used therefor. It is to provide.
- the present inventors have (A) a compound having a specific benzoxazine ring, (B) an epoxy resin, (C) a curing agent, and (D) an improvement in toughness.
- A a compound having a specific benzoxazine ring
- B an epoxy resin
- C a curing agent
- D an improvement in toughness.
- an agent and polyamide 12 particles having a specific particle size in a specific ratio narrower than the conventionally proposed range, and changing the compounding ratio depending on the average particle size of the polyamide 12 particles.
- the present inventors have found that various mechanical properties having a trade-off relationship can be achieved at a high level at the same time.
- R 1 is a chain alkyl group having 1 to 12 carbon atoms, a cyclic alkyl group having 3 to 8 carbon atoms, a phenyl group, or a chain alkyl group having 1 to 12 carbon atoms or a halogen
- the component (B) contains 5 to 20 parts by weight of the component (C), 3 to 20 parts by weight of the component (D) and 20 to 30 parts by weight of the component (E1).
- a dissolved benzoxazine resin composition (hereinafter may be referred to as the first composition of the present invention) is provided.
- the present invention comprises the above components (A) to (D) and (E2) polyamide 12 particles having an average particle size of 15 ⁇ m or more and 60 ⁇ m or less, (A) component 65-78% by mass and (B) component 22-35% by mass so that the total content of component (A) and component (B) is 100% by mass, (B) 5 to 20 parts by mass of component (C), 3 to 20 parts by mass of component (D), and 5 to 20 parts by mass of component (E1) with respect to 100 parts by mass of component (D) )
- a benzoxazine resin composition in which the component is dissolved hereinafter sometimes referred to as the second composition of the present invention
- the reinforcing fiber base material is impregnated with the first composition of the present invention or the second composition of the present invention (hereinafter sometimes referred to collectively as the composition of the present invention).
- a prepreg is provided.
- the fiber reinforced composite material which consists of hardened
- the fiber-reinforced composite material of the present invention employs the composition of the present invention, excellent CAI, ILSS and bending fracture toughness can be achieved simultaneously in a high dimension, and the glass transition temperature of the resin material can be maintained high. . Therefore, the fiber-reinforced composite material of the present invention can be suitably used for aircraft applications, marine applications, automobile applications, sports applications, and other general industrial applications, and is particularly useful for aircraft applications.
- the component (A) used in the composition of the present invention is a benzoxazine resin represented by the above formula (1).
- R 1 is a chain alkyl group having 1 to 12 carbon atoms, substituted with a cyclic alkyl group, a phenyl group, or a chain alkyl group or halogen having 1 to 12 carbon atoms having 3 to 8 carbon atoms And represents a phenyl group.
- Examples of the chain alkyl group having 1 to 12 carbon atoms include a methyl group, an ethyl group, a propyl group, an isopropyl group, an n-butyl group, an isobutyl group, and a t-butyl group.
- Examples of the cyclic alkyl group having 3 to 8 carbon atoms include a cyclopentyl group and a cyclohexyl group.
- Examples of the phenyl group substituted with a chain alkyl group having 1 to 12 carbon atoms or halogen include, for example, o-methylphenyl group, m-methylphenyl group, p-methylphenyl group, o-ethylphenyl group, m- Examples thereof include an ethylphenyl group, a p-ethylphenyl group, an ot-butylphenyl group, an mt-butylphenyl group, a pt-butylphenyl group, an o-chlorophenyl group, and an o-bromophenyl group.
- R 1 is preferably a methyl group, an ethyl group, a propyl group, a phenyl group, or an o-methylphenyl group among the above examples.
- benzoxazine resin of component (A) for example, a monomer represented by the following formula, an oligomer obtained by polymerizing several molecules of the monomer, a compound having a benzoxazine ring having a structure different from these monomers, and at least of these monomers A reaction product with one kind is preferred.
- Component (A) is excellent in flame retardancy because the benzoxazine ring undergoes ring-opening polymerization to form the same skeleton as the phenol resin. In addition, excellent mechanical properties such as low water absorption and high elastic modulus can be obtained from the dense structure.
- Component (B) which is an epoxy resin used in the composition of the present invention, is a component that controls the viscosity of the composition and increases the curability of the composition.
- an epoxy resin having a precursor such as an amine, a phenol, a carboxylic acid, or a compound containing an intramolecular unsaturated carbon is preferable.
- epoxy resins having amines as precursors include tetraglycidyldiaminodiphenylmethane, glycidyl compounds of xylenediamine, triglycidylaminophenol, glycidylaniline, or their respective positional isomers, substituted groups with alkyl groups and halogens. It is done.
- the complex viscoelastic modulus ⁇ * at 25 ° C. obtained by a dynamic viscoelasticity measuring device described later is described as the viscosity.
- triglycidylaminophenol Commercially available products of triglycidylaminophenol include, for example, “jER” 630 (viscosity: 750 mPa ⁇ s) (manufactured by Mitsubishi Chemical Corporation), “Araldite” MY0500 (viscosity: 3500 mPa ⁇ s), MY0510 (viscosity: 600 mPa ⁇ s). s) (manufactured by Huntsman Advanced Materials), ELM100 (viscosity: 16000 mPa ⁇ s) (manufactured by Sumitomo Chemical).
- Examples of commercially available glycidyl anilines include GAN (viscosity: 120 mPa ⁇ s) and GOT (viscosity: 60 mPa ⁇ s) (manufactured by Nippon Kayaku Co., Ltd.).
- Examples of the glycidyl ether type epoxy resin having phenol as a precursor include, for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, epoxy resin having a biphenyl skeleton, phenol novolak type epoxy resin, cresol novolak type Epoxy resin, resorcinol type epoxy resin, epoxy resin having naphthalene skeleton, triphenylmethane type epoxy resin, phenol aralkyl type epoxy resin, dicyclopentadiene type epoxy resin, diphenylfluorene type epoxy resin and various isomers and alkyl groups thereof, Examples include halogen substitution products. Moreover, an epoxy resin obtained by modifying an epoxy resin having a phenol precursor with urethane or isocyanate is also included in this type.
- liquid bisphenol A type epoxy resins examples include “jER” 825 (viscosity: 5000 mPa ⁇ s), “jER” 826 (viscosity: 8000 mPa ⁇ s), and “jER” 827 (viscosity: 10,000 mPa ⁇ s).
- JER 828 viscosity: 13000 mPa ⁇ s
- 850 viscosity: 13000 mPa ⁇ s
- YD-128 viscosity: 13000 mPa ⁇ s
- DER-331 viscosity: 13000 mPa ⁇ s
- DER-332 viscosity: 5000 mPa ⁇ s)
- Examples of commercially available solid or semi-solid bisphenol A type epoxy resins include “jER” 834, “jER” 1001, “jER” 1002, “jER” 1003, “jER” 1004, “jER” 1004AF, and “jER”. "1007", “jER” 1009 (manufactured by Mitsubishi Chemical Corporation).
- liquid bisphenol F-type epoxy resins examples include “jER” 806 (viscosity: 2000 mPa ⁇ s), “jER” 807 (viscosity: 3500 mPa ⁇ s), and “jER” 1750 (viscosity: 1300 mPa ⁇ s).
- Solid bisphenol F type epoxy resins include, for example, 4004P, “jER” 4007P, “jER” 4009P (manufactured by Mitsubishi Chemical Corporation), “Epototo” YDF2001, “Epototo” YDF2004 (above Nippon Steel) Chemical Co., Ltd.).
- Examples of the bisphenol S type epoxy resin include EXA-1515 (manufactured by DIC Corporation).
- Examples of commercially available epoxy resins having a biphenyl skeleton include “jER” YX4000H, “jER” YX4000, “jER” YL6616 (manufactured by Mitsubishi Chemical Corporation), NC-3000 (manufactured by Nippon Kayaku Co., Ltd.). ).
- Examples of commercially available phenol novolac epoxy resins include “jER” 152, “jER” 154 (manufactured by Mitsubishi Chemical Corporation), “Epicron” N-740, “Epicron” N-770, “Epicron” N -775 (manufactured by DIC Corporation).
- Examples of commercially available cresol novolac type epoxy resins include “Epiclon” N-660, “Epicron” N-665, “Epicron” N-670, “Epicron” N-673, “Epicron” N-695 (above, DIC Corporation), EOCN-1020, EOCN-102S, EOCN-104S (above, Nippon Kayaku Co., Ltd.).
- Examples of commercially available resorcinol-type epoxy resins include “Denacol” (registered trademark, hereinafter the same) EX-201 (viscosity: 250 mPa ⁇ s) (manufactured by Nagase ChemteX Corporation).
- Examples of commercially available epoxy resins having a naphthalene skeleton include “Epiclon” HP4032 (manufactured by DIC Corporation), NC-7000, NC-7300 (manufactured by Nippon Kayaku Co., Ltd.).
- Examples of commercially available trisphenylmethane type epoxy resins include TMH-574 (manufactured by Sumitomo Chemical Co., Ltd.).
- dicyclopentadiene type epoxy resins include, for example, “Epicron” HP7200, “Epicron” HP7200L, “Epicron” HP7200H (above, manufactured by DIC Corporation), “Tactix” (registered trademark) 558 (Huntsman Advanced) -Materials Co., Ltd.), XD-1000-1L, XD-1000-2L (Nippon Kayaku Co., Ltd.).
- examples of commercially available urethane and isocyanate-modified epoxy resins include AER4152 (produced by Asahi Kasei E-Materials Co., Ltd.) having an oxazolidone ring.
- Examples of the epoxy resin using carboxylic acid as a precursor include glycidyl compounds of phthalic acid, glycidyl compounds of hexahydrophthalic acid and dimer acid, and various isomers thereof.
- diglycidyl phthalate examples include, for example, “Epomic” (registered trademark, the same applies hereinafter) R508 (viscosity: 4000 mPa ⁇ s) (manufactured by Mitsui Chemicals), “Denacol” EX-721 (viscosity: 980 mPas). S) (manufactured by Nagase ChemteX Corporation).
- hexahydrophthalic acid diglycidyl ester Commercially available products of hexahydrophthalic acid diglycidyl ester include, for example, “Epomic” R540 (viscosity: 350 mPa ⁇ s) (manufactured by Mitsui Chemicals), AK-601 (viscosity: 300 mPa ⁇ s) (Nippon Kayaku Co., Ltd.) Co., Ltd.).
- dimer acid diglycidyl esters include “jER” 871 (viscosity: 650 mPa ⁇ s) (manufactured by Mitsubishi Chemical Corporation), “Epototo” YD-171 (viscosity: 650 mPa ⁇ s) (Nippon Steel). Chemical Co., Ltd.).
- an alicyclic epoxy resin is mentioned, for example.
- an alicyclic epoxy resin is mentioned, for example.
- a commercially available product of (3 ′, 4′-epoxycyclohexane) methyl-3,4-epoxycyclohexanecarboxylate for example, “Celoxide” (registered trademark, the same shall apply hereinafter) 2021P (viscosity: 250 mPa ⁇ s) ) (Manufactured by Daicel Chemical Industries, Ltd.), CY179 (viscosity: 400 mPa ⁇ s) (manufactured by Huntsman Advanced Materials), (3 ′, 4′-epoxycyclohexane) octyl 3,4-epoxycyclohexanecarboxylate commercially available Examples of the product include “Celoxide” 2081 (viscosity: 100 mPa ⁇ s) (manufactured by Da
- an epoxy resin solid at 25 ° C. an epoxy resin having a high aromatic content is preferable in order to increase flame retardancy.
- the content ratio of the component (A) and the component (B) is 65 to 78% by mass, preferably 70 to 75% by mass, so that the total of these components is 100% by mass.
- Examples of the curing agent for the component (C) in the composition of the present invention include aromatic amines such as diethyltoluenediamine, metaphenylenediamine, diaminodiphenylmethane, diaminodiphenylsulfone, metaxylenediamine, and various derivatives thereof; triethylenetetramine Aliphatic amines such as isophoronediamine; imidazole derivatives; dicyandiamide; tetramethylguanidine; carboxylic acid anhydrides such as methylhexahydrophthalic anhydride; carboxylic acid hydrazides such as adipic hydrazide; carboxylic acid amides; monofunctional phenols; Polyfunctional phenolic compounds such as A; sulfonic acid esters such as bis (4-hydroxyphenyl) sulfide; polyphenolic compounds; polymercaptan; carboxylate; boron trifluoride ethylamine complex Can be used alone or in
- the content of the component (C) is 5 to 20 parts by mass, preferably 7 to 15 parts by mass with respect to 100 parts by mass of the component (A) + the component (B). If the amount is less than 5 parts by mass, the curing reaction is slow, so that a high temperature and a long time are required to increase the degree of curing of the entire resin composition. If it exceeds 20 parts by mass, mechanical properties such as glass transition temperature of the cured product may be lowered.
- the toughness improver of component (D) is a component that dissolves in the composition of the present invention, and consists of organic fine particles or those obtained by dissolving organic fine particles in a liquid resin or resin monomer. There may be mentioned at least one selected from the group.
- dissolution means that the fine particles of component (D) are dispersed in the composition, and the fine particles and the substances constituting the composition have an affinity for each other and are in a uniform or mixed state. means.
- liquid resins or resin monomers examples include reactive elastomers, hiker CTBN-modified epoxy resins, hiker CTB-modified epoxy resins, urethane-modified epoxy resins, nitrile rubber-added epoxy resins, crosslinked acrylic rubber fine particle-added epoxy resins, silicone-modified epoxy resins, A thermoplastic elastomer-added epoxy resin can be used.
- thermosetting resin fine particles for example, thermosetting resin fine particles, thermoplastic resin fine particles, or a mixture thereof can be used.
- thermosetting resin fine particles include epoxy resin fine particles, phenol resin fine particles, melamine resin fine particles, urea resin fine particles, silicone resin fine particles, urethane resin fine particles, or a mixture thereof.
- thermoplastic resin fine particles examples include copolymerized polyester resin fine particles, phenoxy resin fine particles, polyimide resin fine particles, polyamide resin fine particles, acrylic fine particles, butadiene-acrylonitrile resin fine particles, styrene fine particles, olefin fine particles, nylon fine particles, butadiene. -Alkyl methacrylate / styrene copolymer, acrylic ester / methacrylic ester copolymer, or a mixture thereof.
- Nanostrength M22 (trade name, manufactured by Arkema Co., Ltd.), which is commercially available as a copolymer comprising methyl methacrylate / butyl acrylate / methyl methacrylate, can also be used.
- core / shell type fine particles Staphyloid AC3355 (trade name, manufactured by Ganz Kasei Co., Ltd.), MX120 (trade name, manufactured by Kaneka Corporation) and the like can be used.
- the acrylic fine particles can be produced by (1) monomer polymerization, (2) polymer chemical treatment, (3) polymer mechanical pulverization, etc., but the method (3) gives a fine product. Therefore, it is not preferable because the shape is irregular.
- the polymerization method include emulsion polymerization, soap-free emulsion polymerization, dispersion polymerization, seed polymerization, suspension polymerization, or a method in which these are used in combination with each other, the particle size is fine, partially crosslinked structure, core / shell structure, Emulsion polymerization and seed polymerization are used in which fine particles having a hollow structure and a polar structure (epoxy group, carboxyl group, hydroxyl group, etc.) are obtained.
- a polar structure epoxy group, carboxyl group, hydroxyl group, etc.
- Staphyloid AC3355 (trade name, manufactured by Takeda Pharmaceutical Co., Ltd.), F351 (trade name, manufactured by Nippon Zeon Co., Ltd.), Kureha Paraloid EXL-2655 (trade name, Kureha Chemical) Kogyo Co., Ltd.), MX120 (trade name, manufactured by Kaneka Corporation) and the like.
- the content ratio of the component (D) used for improving the toughness of the resin in the composition of the present invention is 3 to 20 parts by mass, preferably 100 parts by mass of the component (A) + the component (B), preferably 5 to 15 parts by mass. If the amount is less than 3 parts by mass, the resin composition has low toughness and cracks may occur during curing of the resin composition. If the amount exceeds 20 parts by mass, the heat resistance of the resin composition may decrease.
- the polyamide 12 particles of the component (E1) or component (E2) used in the composition of the present invention can maintain a powder state in the composition of the present invention, preferably those having a melting point of 170 ° C. or more, A temperature of 175 to 185 ° C. is desirable.
- the melting point is a temperature at which the heat of fusion reaches a peak when measured with a differential scanning calorimeter at a rate of temperature increase of 10 ° C./min.
- the average particle size of the polyamide 12 powder of component (E1) is 1 ⁇ m or more and less than 15 ⁇ m, preferably 5 ⁇ m or more and less than 15 ⁇ m.
- the average particle size of the polyamide 12 powder of component (E2) is 15 ⁇ m or more and 60 ⁇ m or less, preferably 15 ⁇ m or more and 30 ⁇ m or less.
- the reason why the (E1) component and the (E2) component are separated according to the average particle diameter is that the desired effect of the present invention cannot be obtained unless the content ratio of these components described later is controlled to be different.
- the average particle diameter means an average value of the lengths of the long diameters of each particle measured with 100 particles arbitrarily selected from 200-500 times enlarged particles with a scanning electron microscope (SEM). To do.
- the polyamide 12 particles used in the present invention examples include “VESTOSINT1111, VESTOSINT2070, VESTOSINT2157, VESTOSINT2158, and VESTOSINT2159 (registered trademark, manufactured by Daicel Evonik Co., Ltd.).
- the polyamide 12 particles are preferably spherical particles from the viewpoint of not reducing the flow characteristics of the composition of the present invention, but may be non-spherical particles.
- the content ratio of the component (E1) is 20 to 30 parts by mass, preferably 20 to 25 parts by mass with respect to 100 parts by mass of the component (A) + the component (B). If it is less than 20 parts by mass, the CAI decreases, and if it exceeds 30 parts by mass, the ILSS may decrease.
- the content ratio of the component (E2) is 5 parts by weight or more and less than 20 parts by weight, preferably 7 to 18 parts by weight with respect to 100 parts by weight of the component (A) + the component (B). It is. If it is less than 5 parts by mass, the CAI and toughness are lowered, and if it is 20 parts by mass or more, the ILSS is lowered and the desired effect of the present invention may not be obtained.
- nanocarbon for example, nanocarbon, a flame retardant, a release agent, and the like can be blended within a range that does not impair the physical properties.
- nanocarbon include carbon nanotubes, fullerenes, and derivatives thereof.
- flame retardant include red phosphorus; phosphoric acid such as triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, xylenyl diphenyl phosphate, resorcinol bisphenyl phosphate, bisphenol A bisdiphenyl phosphate, etc. Ester; boric acid ester and the like.
- the mold release agent include silicone oil, stearic acid ester, carnauba wax and the like.
- the method for kneading the composition of the present invention is not particularly limited.
- a kneader, a planetary mixer, a twin screw extruder or the like is used.
- the particles are previously diffused into the liquid resin component to be blended in the benzoxazine resin composition with a homomixer, three rolls, a ball mill, a bead mill, and an ultrasonic wave.
- heating / cooling, pressurization / depressurization may be performed as necessary.
- the viscosity of the composition of the present invention is preferably 10 to 3000 Pa ⁇ s at 50 ° C. from the viewpoint of tack and drape. More preferably, it is 10 to 2500 Pa ⁇ s, and most preferably 100 to 2000 Pa ⁇ s. If it is less than 10 Pa ⁇ s, the change with time of the tack due to the sinking of the composition of the present invention may become large. On the other hand, when it exceeds 3000 Pa ⁇ s, the tack becomes weak, and the drape property may be lowered.
- the reinforcing fiber of the reinforcing fiber base for example, glass fiber, carbon fiber, graphite fiber, aramid fiber, boron fiber, alumina fiber, and silicon carbide fiber are preferable. Two or more kinds of these fibers may be mixed and used, but carbon fibers and graphite fibers are preferably used in order to obtain a molded product that is lighter and more durable.
- any type of carbon fiber or graphite fiber can be used depending on the application, but since a composite material having excellent impact resistance and high rigidity and mechanical strength can be obtained, the strand tensile test
- the tensile modulus of elasticity is preferably 150 to 650 GPa, more preferably 200 to 550 GPa, still more preferably 230 to 500 GPa.
- the strand tensile test refers to a test carried out based on JIS R7601 (1986) after impregnating a bundle of carbon fibers with a resin having the following composition and curing it at a temperature of 130 ° C. for 35 minutes.
- the form of the reinforcing fiber base is not particularly limited.
- long fibers, tows, woven fabrics, mats, knits, braids, and a length of less than 10 mm are aligned in one direction.
- Short fibers that are chopped are used.
- the long fiber is a single fiber or a fiber bundle substantially continuous for 10 mm or more.
- a short fiber is a fiber bundle cut into a length of less than 10 mm.
- an array in which reinforcing fiber bundles are aligned in a single direction is most suitable for applications that require a high specific strength and specific elastic modulus. Arrangements are also suitable for the present invention.
- the prepreg of the present invention is obtained by impregnating a reinforcing fiber base material with the composition of the present invention.
- the impregnation method include a wet method in which the composition of the present invention is dissolved in a solvent such as methyl ethyl ketone and methanol to lower the viscosity and impregnation, a hot melt method in which the viscosity is reduced by heating and impregnation (dry method), and the like. Can do.
- the wet method is a method in which a reinforcing fiber substrate is immersed in a solution of a benzoxazine resin composition, then lifted and the solvent is evaporated using an oven or the like.
- the hot melt method is a benzoxazine resin whose viscosity is reduced by heating.
- a method of impregnating the reinforcing fiber base directly with the composition, or a film in which the benzoxazine resin composition is once coated on a release paper or the like is prepared, and then the film is laminated from both sides or one side of the reinforcing fiber base.
- the reinforcing fiber base material is impregnated with resin by heating and pressing.
- the hot melt method is preferable because substantially no solvent remains in the prepreg.
- the amount of reinforcing fibers of the reinforcing fiber base per unit area is preferably 70 to 3000 g / m 2 .
- the amount of reinforcing fibers is less than 70 g / m 2, it is necessary to increase the number of laminated layers in order to obtain a predetermined thickness when forming a fiber reinforced composite material, and the work may be complicated.
- the amount of reinforcing fibers exceeds 3000 g / m 2 , the prepreg drapability tends to deteriorate. If the prepreg is flat or simple, the amount of reinforcing fibers may exceed 3000 g / m 2 .
- the fiber weight content is preferably 30 to 90% by mass, more preferably 35 to 85% by mass, and still more preferably 40 to 80% by mass.
- the fiber weight content is less than 30% by mass, the amount of the resin is too large to obtain the advantages of the fiber reinforced composite material excellent in specific strength and specific elastic modulus, or when the fiber reinforced composite material is molded at the time of curing. The amount of heat generated may be too large.
- the fiber weight content exceeds 90% by weight, resin impregnation failure occurs, and the resulting composite material may have many voids.
- the prepreg of the present invention can be made into the fiber-reinforced composite material of the present invention by, for example, a method of heat-curing resin while applying pressure to the laminate after lamination.
- methods for applying heat and pressure include a press molding method, an autoclave molding method, a vacuum molding method, a wrapping tape method, and an internal pressure molding method.
- the wrapping tape method is a method of winding a prepreg around a mandrel or other core metal to form a tubular body made of a fiber-reinforced composite material, and is a method suitable for producing a rod-shaped body such as a golf shaft or fishing rod. .
- a prepreg is wound around a mandrel, a wrapping tape made of a thermoplastic film is wound around the outside of the prepreg for fixing and applying pressure, and the resin is heated and cured in an oven, and then a cored bar.
- This is a method for extracting a tube to obtain a tubular body.
- a preform obtained by winding a prepreg on an internal pressure applying body such as a tube made of a thermoplastic resin is set in a mold, and then a high pressure gas is introduced into the internal pressure applying body to apply pressure and at the same time
- the mold is heated and molded.
- This method is preferably used when molding a complicated shape such as a golf shaft, a bat, a racket such as tennis or badminton.
- the fiber-reinforced composite material of the present invention can also be obtained by directly impregnating a base material with a resin composition and curing it.
- a method of placing a reinforcing fiber base in a mold and then pouring, impregnating and curing the composition of the present invention, laminating a film comprising the reinforcing fiber base and the composition of the present invention, and laminating the laminate can also be produced by a method of heating and pressurizing.
- the film made of the composition of the present invention refers to a film obtained by applying a predetermined amount of the composition in a uniform thickness on a release paper or a release film in advance.
- examples of the reinforcing fiber base include long fibers arranged in one direction, two-way woven fabric, non-woven fabric, mat, knit, braided string, and the like. Lamination includes not only simply superimposing fiber base materials, but also includes cases where they are attached to various molds and core materials to be preformed.
- a foam core or a honeycomb core is preferably used.
- the foam core urethane or polyimide is preferably used.
- honeycomb core an aluminum core, a glass core, an aramid core, or the like is preferably used.
- the fiber reinforced composite material of the present invention has a post-impact compressive strength (CAI) of usually 250 MPa or more, preferably 290 MPa or more, and an interlayer shear strength (ILSS) of usually 45 MPa or more, preferably measured under the conditions in Examples described later. Is 50 MPa or more, the bending fracture toughness is usually 1.0 MPa ⁇ m 1/2 or more, preferably 1.2 MPa ⁇ m 1/2 or more, and the composition of the present invention is cured at 180 ° C. for 2 hours. Since the glass transition temperature of the cured product is usually 180 ° C. or higher, preferably 190 ° C. or higher, excellent CAI, ILSS and bending fracture toughness can be achieved at a high level at the same time, and the glass transition temperature of the resin material is also excellent. It is suitably used for railway vehicles, aircraft, building members, and other general industrial applications.
- CAI post-impact compressive strength
- ILSS interlayer shear strength
- ⁇ Prepreg tackiness test> The obtained benzoxazine resin composition was applied onto release paper to obtain a resin film.
- the resin film was supplied from above and below carbon fibers aligned in one direction and impregnated to prepare a prepreg.
- the amount of carbon fiber per unit area of this prepreg was 150 g / m 2
- the amount of matrix resin was 67 g / m 2 .
- the tack of the obtained prepreg was determined by a tactile sensation method. Immediately after peeling off the release paper from the surface of the prepreg, press the prepreg with your finger and select “++” for a moderately tacky or “++” for a slightly too strong or slightly weaker one. “+” Indicates that there was no contact with the finger.
- the obtained prepreg was quasi-isotropically laminated with 32 plies in a [+ 45 ° / 0 ° / ⁇ 45 ° / 90 °] 4s configuration and heated in an autoclave at a temperature of 180 ° C. and a pressure of 0.6 MPa for 2 hours. Cured to obtain CFRP.
- CFRP according to SACMA SRM 2R-94, a sample having a length of 150 mm and a width of 100 mm was cut out, a drop weight impact of 6.7 J / mm was applied to the center of the sample, and the compressive strength after impact was determined.
- the toughness of the cured resin refers to the critical stress strength of deformation mode 1 (opening type).
- Comparative Example 1 does not contain (E) component and therefore has low CAI and bending fracture toughness
- Comparative Example 2 does not contain (D) component and has a high content of (E) component, so ILSS
- the bending fracture toughness is low and the prepreg tackiness is poor.
- Comparative Example 3 since the component (D) is not included, the bending fracture toughness is low.
- Comparative Example 4 the content ratio of the component (A) is low.
- B) Since the content ratio of the component is high, the ILSS and the glass transition temperature are low.
- Comparative Example 5 the content ratio of the bisphenol A type epoxy resin is high, so that the glass transition temperature is low.
- Comparative Example 6 the component (A) Since the content ratio is high and the content ratio of the component (B) is low, the viscosity is high and a prepreg cannot be prepared. In Comparative Example 7, the content ratio of the component (D) is high, so the glass transition temperature is low. In 8 and 9, the content ratio of component (E) is high LSS is it was found, respectively low.
Abstract
Description
近年、その使用実績を積むに従い、繊維強化複合材料の適用範囲はますます拡がっている。
このような繊維強化複合材料として、ベンゾオキサジン環を有する化合物を利用したものが、例えば、特許文献1及び2に提案されている。該ベンゾオキサジン環を有する化合物は、優れた耐湿性及び耐熱性を有するが、靱性に劣る問題があり、エポキシ樹脂や各種樹脂微粒子等を配合してその欠点を補う工夫がなされている。
ところで、特に、航空機用途で必要とされる力学特性の中でも衝撃後圧縮強度(以下CAIと略す)、高温高湿時における層間剪断強度(以下ILSSと略す)及び曲げ破壊靱性等を高次元で同時に達成させることで、材料の更なる軽量化が望まれている。加えて、高温特性を維持するために、使用する樹脂材料のガラス転移温度も高く維持する必要がある。しかし、上記特許文献に具体的に記載された例では、必ずしもこれらが高次元で同時に達成できるとは言えない。
上記力学特性を向上させる技術として、例えば、特許文献3には、CAIを向上させる目的で、エポキシ樹脂等の熱硬化性樹脂にポリアミド12微粒子を配合する技術が開示されている。
このような技術を利用した繊維強化複合材料は、CAIをある程度高く維持することは可能であるが、高温高湿時におけるILSSを両立させるには至っていない。
従って、現在使用されている複合材料を代替する場合、現状よりも軽量化を進めるためにより高い各種機械物性を同時に有する材料の開発が要求されている。
(B)エポキシ樹脂と、(C)硬化剤と、(D)靭性向上剤と、(E1)平均粒径1μm以上15μm未満のポリアミド12粒子とを含み、
(A)成分及び(B)成分の含有割合が合計100質量%となるように、(A)成分65~78質量%、及び(B)成分22~35質量%を含み、(A)成分及び(B)成分の合計100質量部に対して、(C)成分5~20質量部、(D)成分3~20質量部及び(E1)成分20~30質量部含有し、(D)成分が溶解しているベンゾオキサジン樹脂組成物(以下、本発明の第1の組成物という場合がある)が提供される。
また本発明によれば、上記(A)~(D)成分と、(E2)平均粒径15μm以上60μm以下のポリアミド12粒子とを含み、
(A)成分及び(B)成分の含有割合が合計100質量%となるように、(A)成分65~78質量%、及び(B)成分22~35質量%を含み、(A)成分及び(B)成分の合計100質量部に対して、(C)成分5~20質量部、(D)成分3~20質量部及び(E1)成分5質量部以上20質量部未満含有し、(D)成分が溶解しているベンゾオキサジン樹脂組成物(以下、本発明の第2の組成物という場合がある)が提供される。
更に本発明によれば、上記本発明の第1の組成物又は本発明の第2の組成物(以下、まとめて本発明の組成物ということがある)を強化繊維基材に含浸してなるプリプレグが提供される。
更にまた本発明によれば、本発明の組成物の硬化物と強化繊維基材とからなる繊維強化複合材料が提供される。
本発明の組成物に用いる(A)成分は、上記式(1)で表されるベンゾオキサジン樹脂である。
式(1)において、R1は、炭素数1~12の鎖状アルキル基、炭素数3~8の環状アルキル基、フェニル基、又は炭素数1~12の鎖状アルキル基若しくはハロゲンで置換された、フェニル基を示す。
炭素数1~12の鎖状アルキル基としては、例えば、メチル基、エチル基、プロピル基、イソプロピル基、n-ブチル基、イソブチル基、t-ブチル基が挙げられる。
炭素数3~8の環状アルキル基としては、例えば、シクロペンチル基、シクロヘキシル基が挙げられる。
炭素数1~12の鎖状アルキル基若しくはハロゲンで置換された、フェニル基としては、例えば、o-メチルフェニル基、m-メチルフェニル基、p-メチルフェニル基、o-エチルフェニル基、m-エチルフェニル基、p-エチルフェニル基、o-t-ブチルフェニル基、m-t-ブチルフェニル基、p-t-ブチルフェニル基、o-クロロフェニル基、o-ブロモフェニル基が挙げられる。
R1としては、上記例示の中でも、良好な取り扱い性を与えることから、メチル基、エチル基、プロピル基、フェニル基、o-メチルフェニル基が好ましい。
(B)成分としては、例えば、アミン類、フェノール類、カルボン酸、分子内不飽和炭素を含む化合物等の化合物を前駆体とするエポキシ樹脂が好ましい。
以下、市販品を例示する場合、液状のものには、後述の動的粘弾性測定装置により得られる25℃における複素粘弾性率η*を粘度として記載している。
グリシジルアニリン類の市販品としては、例えば、GAN(粘度:120mPa・s)、GOT(粘度:60mPa・s)(以上日本化薬(株)製)が挙げられる。
また、フェノールを前駆体とするエポキシ樹脂をウレタンやイソシアネートで変性したエポキシ樹脂も、このタイプに含まれる。
固形もしくは半固形のビスフェノールA型エポキシ樹脂の市販品としては、例えば、「jER」834、「jER」1001、「jER」1002、「jER」1003、「jER」1004、「jER」1004AF、「jER」1007、「jER」1009(以上三菱化学(株)製)が挙げられる。
固形のビスフェノールF型エポキシ樹脂の市販品としては、例えば、4004P、「jER」4007P、「jER」4009P(以上三菱化学(株)製)、「エポトート」YDF2001、「エポトート」YDF2004(以上新日鐵化学(株)製)が挙げられる。
ビフェニル骨格を有するエポキシ樹脂の市販品としては、例えば、「jER」YX4000H、「jER」YX4000、「jER」YL6616(以上、三菱化学(株)製)、NC-3000(日本化薬(株)製)が挙げられる。
クレゾールノボラック型エポキシ樹脂の市販品としては、例えば、「エピクロン」N-660、「エピクロン」N-665、「エピクロン」N-670、「エピクロン」N-673、「エピクロン」N-695(以上、DIC(株)製)、EOCN-1020、EOCN-102S、EOCN-104S(以上、日本化薬(株)製)が挙げられる。
ナフタレン骨格を有するエポキシ樹脂の市販品としては、例えば、「エピクロン」HP4032(DIC(株)製)、NC-7000、NC-7300(以上、日本化薬(株)製)が挙げられる。
トリスフェニルメタン型エポキシ樹脂の市販品としては、例えば、TMH-574(住友化学(株)製)が挙げられる。
ウレタンおよびイソシアネート変性エポキシ樹脂の市販品としては、例えば、オキサゾリドン環を有するAER4152(旭化成イーマテリアルズ(株)製)が挙げられる。
ヘキサヒドロフタル酸ジグリシジルエステルの市販品としては、例えば、「エポミック」R540(粘度:350mPa・s)(三井化学(株)製)、AK-601(粘度:300mPa・s)(日本化薬(株)製)が挙げられる。
ダイマー酸ジグリシジルエステルの市販品としては、例えば、「jER」871(粘度:650mPa・s)(三菱化学(株)製)、「エポトート」YD-171(粘度:650mPa・s)(新日鐵化学(株)製)が挙げられる。
具体的には、(3',4'-エポキシシクロヘキサン)メチル-3,4-エポキシシクロヘキサンカルボキシレートの市販品としては、例えば、「セロキサイド」(登録商標、以下同じ)2021P(粘度:250mPa・s)(ダイセル化学工業(株)製)、CY179(粘度:400mPa・s)(ハンツマン・アドバンスドマテリアルズ社製)、(3',4'-エポキシシクロヘキサン)オクチル3,4-エポキシシクロヘキサンカルボキシレートの市販品としては、例えば、「セロキサイド」2081(粘度:100mPa・s)(ダイセル化学工業(株)製)、1-メチル-4-(2-メチルオキシラニル)-7-オキサビスシクロ[4.1.0]ヘプタンの市販品としては、例えば、「セロキサイド」3000(粘度:20mPa・s)(ダイセル化学工業(株)製)が挙げられる。
25℃で固形のエポキシ樹脂としては、芳香族含有量の高いエポキシ樹脂が難燃性を高めるために好ましく、例えば、ビフェニル骨格をもつエポキシ樹脂や、ナフタレン骨格をもつエポキシ樹脂、フェノールアラルキル型エポキシ樹脂が挙げられる。
これら硬化剤は(A)成分のベンゾオキサジンや(B)成分のエポキシ樹脂と反応することで、耐熱・耐湿性に優れる樹脂組成物あるいは繊維強化複合材料を得ることができる。
ここで溶解とは、(D)成分の微粒子が組成物中に分散し、当該微粒子と組成物を構成する物質とが相互に親和性を有し、均一または混和した状態となっていることを意味する。
液状樹脂あるいは樹脂モノマーとしては、例えば、反応性エラストマー、ハイカーCTBN変性エポキシ樹脂、ハイカーCTB変性エポキシ樹脂、ウレタン変性エポキシ樹脂、ニトリルゴム添加エポキシ樹脂、架橋アクリルゴム微粒子添加エポキシ樹脂、シリコーン変性エポキシ樹脂、熱可塑性エラストマー添加エポキシ樹脂が使用できる。
熱硬化性樹脂微粒子としては、例えば、エポキシ樹脂微粒子、フェノール樹脂微粒子、メラミン樹脂微粒子、ウレア樹脂微粒子、シリコーン樹脂微粒子、ウレタン樹脂微粒子またはこれらの混合物等が挙げられる。
またアクリル系微粒子としては、メタクリル酸メチル・ブチルアクリレート・メタクリル酸メチルからなる共重合体として市販されている、Nanostrength M22(商品名、アルケマ社製)を利用することもできる。
コア/シェル型微粒子の市販されているものとして、スタフィロイドAC3355(商品名、ガンツ化成(株)製)、MX120(商品名、カネカ社製)等も利用することができる。
重合法としては、例えば、乳化重合、ソープフリー乳化重合、分散重合、シード重合、懸濁重合またはこれらを互いに併用した方法があり、粒径が微細で、一部架橋構造、コア/シェル構造、中空構造、極性構造(エポキシ基、カルボキシル基、水酸基など)を有する微粒子が得られる、乳化重合、シード重合が用いられる。
コア/シェル型微粒子の市販されているものとして、スタフィロイドAC3355(商品名、武田薬品工業社製)、F351(商品名、日本ゼオン社製)、クレハパラロイドEXL-2655(商品名、呉羽化学工業社製)、MX120(商品名、カネカ社製)等が挙げられる。
(E1)成分のポリアミド12粉末の平均粒径は、1μm以上15μm未満、好ましくは5μm以上15μm未満である。(E2)成分のポリアミド12粉末の平均粒径は、15μm以上60μm以下、好ましくは15μm以上30μm以下である。このように、平均粒径により(E1)成分と(E2)成分とを分けている理由は、後述するこれら成分の含有割合を異なるように制御しないと、本発明の所望の効果が得られないからである。
ここで、平均粒径は、走査型電子顕微鏡(SEM)にて200~500倍に拡大した粒子の任意に選択した100個の粒子について測定した、各粒子の長径の長さの平均値を意味する。
ポリアミド12粒子は、本発明の組成物の流動特性を低下させない点から球状粒子が好ましいが、非球状粒子でもよい。
本発明の第2の組成物において(E2)成分の含有割合は、(A)成分+(B)成分100質量部に対して、5質量部以上20質量部未満、好ましくは7~18質量部である。5質量部未満では、CAIおよび靱性が低下し、20質量部以上ではILSSが低下し、本発明の所望の効果が得られないおそれがある。
ナノカーボンとしては、例えば、カーボンナノチューブ、フラーレンやそれぞれの誘導体が挙げられる。
難燃剤としては、例えば、赤燐;トリフェニルホスフェート、トリクレジルホスフェート、トリキシレニルホルフェート、クレジルジフェニルホスフェート、キシレニルジフェニルホスフェート、レゾルシノールビスフェニルホスフェート、ビスフェノールAビスジフェニルホスフェート等のリン酸エステル;ホウ酸エステル等が挙げられる。
離型剤としては、例えば、シリコンオイル、ステアリン酸エステル、カルナウバワックス等が挙げられる。
本発明においては、用途に応じてあらゆる種類の炭素繊維や黒鉛繊維を用いることが可能であるが、耐衝撃性に優れ、高い剛性および機械強度を有する複合材料を得られることから、ストランド引張試験における引張弾性率が150~650GPaであることが好ましく、より好ましくは200~550GPaであり、さらに好ましくは230~500GPaである。
なお、ストランド引張試験とは、束状の炭素繊維に下記組成の樹脂を含浸させ、130℃の温度で35分間硬化させた後、JIS R7601(1986)に基づいて行う試験をいう。
ここで、長繊維とは実質的に10mm以上連続な単繊維もしくは繊維束である。短繊維とは10mm未満の長さに切断された繊維束である。また、特に、比強度、比弾性率が高いことを要求される用途には強化繊維束が単一方向に引き揃えられた配列が最も適しているが、取り扱いの容易なクロス(織物)状の配列も本発明には適している。
含浸させる方法としては、本発明の組成物をメチルエチルケトン、メタノール等の溶媒に溶解して低粘度化し、含浸させるウェット法、加熱により低粘度化し、含浸させるホットメルト法(ドライ法)等を挙げることができる。
ウェット法は、強化繊維基材をベンゾオキサジン樹脂組成物の溶液に浸漬した後、引き上げ、オーブン等を用いて溶媒を蒸発させる方法であり、ホットメルト法は、加熱により低粘度化したベンゾオキサジン樹脂組成物を直接強化繊維基材に含浸させる方法、又は一旦ベンゾオキサジン樹脂組成物を離型紙等の上にコーティングしたフィルムを作製しておき、次いで強化繊維基材の両側又は片側から前記フィルムを重ね、加熱加圧することにより強化繊維基材に樹脂を含浸させる方法である。
ホットメルト法においては、プリプレグ中に残留する溶媒が実質上皆無となるため好ましい。
ここで熱及び圧力を付与する方法には、例えば、プレス成形法、オートクレーブ成形法、バキューム成形法、ラッピングテープ法、内圧成形法が挙げられる。
ラッピングテープ法は、マンドレル等の芯金にプリプレグを捲回して、繊維強化複合材料製の管状体を成形する方法であり、ゴルフシャフト、釣り竿等の棒状体を作製する際に好適な方法である。より具体的には、マンドレルにプリプレグを捲回し、プリプレグの固定及び圧力付与のため、プリプレグの外側に熱可塑性フィルムからなるラッピングテープを捲回し、オーブン中で樹脂を加熱硬化させた後、芯金を抜き取って管状体を得る方法である。
本発明の組成物からなるフィルムとは、予め離型紙や離型フィルム上に所定量の組成物を均一な厚みで塗布したものを指す。ここで強化繊維基材としては、一方向に引き揃えた長繊維、二方向織物、不織布、マット、ニット、組み紐などが挙げられる。
積層とは、単に繊維基材を重ね合わせる場合のみならず、各種型やコア材に貼り付けてプリフォームする場合も含むものである。
コア材としては、フォームコアやハニカムコアなどが好ましく用いられる。フォームコアとしては、ウレタンやポリイミドが好ましく用いられる。ハニカムコアとしてはアルミコアやガラスコア、アラミドコアなどが好ましく用いられる。
実施例1~5、比較例1~9
各実施例、比較例について、表1及び表2に示す割合で原料を混合し、ベンゾオキサジン樹脂組成物を得た。
なお、ここで用いた原料は以下に示す通りである。
(A)成分:ベンゾオキサジン樹脂
F-a(ビスフェノールF-アニリン型、四国化成(株)製)
P-a(フェノール-アニリン型、四国化成(株)製)
(B)成分:エポキシ樹脂
「セロキサイド」(登録商標)2021P(ダイセル化学工業(株)製)
ビスフェノールA型ジグリシジルエーテル(YD-128、新日鐵化学(株)製)
(C)成分:硬化剤
ビス(4-ヒドロキシフェニル)スルフィド(東京化成(株)製)
(D)成分:靭性向上剤
Nanostrength (M22、アルケマ社製)
フェノキシ樹脂(YP-70、新日鐵化学(株)製)
(E)成分
「VESTOSINT」(登録商標)2157(平均粒径55μmのポリアミド12、ダイセル・エボニック株式会社製)
「VESTOSINT」(登録商標)2158(平均粒径20μmのポリアミド12、ダイセル・エボニック株式会社製)
「VESTOSINT」(登録商標)2159(平均粒径10μmのポリアミド12、ダイセル・エボニック株式会社製)
「VESTOSINT」(登録商標)2170(平均粒径5μmのポリアミド12、ダイセル・エボニック株式会社製)
得られたベンゾオキサジン樹脂組成物を、180℃のオーブン中で2時間硬化して樹脂硬化物を得た。得られた硬化物を、示差熱量計(DSC)を用いて、JIS K7121(1987)に基づいて求めた中間点温度をガラス転移温度として測定した。
得られたベンゾオキサジン樹脂組成物を用いて離型紙上に塗布し、樹脂フィルムを得た。該樹脂フィルムを、一方向に引き揃えた炭素繊維の上下から供給して含浸し、プリプレグを作製した。このプリプレグの単位面積当たりの炭素繊維量は150g/m2、マトリックス樹脂量は67g/m2であった。
得られたプリプレグのタックを触感法で判定した。プリプレグ表面から離型紙を引き剥がした直後に指でプリプレグを押さえタックの程よいものを「+++」、やや強すぎるもしくはやや弱いものを「++」、タックが強すぎて指から剥がれないものや全くタックがなく指につかないものを「+」とした。
得られたプリプレグを、[+45°/0°/-45°/90°]4s構成で、擬似等方的に32プライ積層し、オートクレーブにて、温度180℃、圧力0.6MPaで2時間加熱硬化し、CFRPを得た。このCFRPについて、SACMA SRM 2R-94に従い、縦150mm×横100mmのサンプルを切り出し、サンプルの中心部に6.7J/mmの落錘衝撃を与え、衝撃後圧縮強度を求めた。
得られたプリプレグを、0度方向に12層積層し、オートクレーブ中で温度180℃、圧力0.6MPaで2時間加熱硬化し、CFRPを得た。このCFRPについて、ASTM D2402-07に従い、0度方向が13mm、幅方向が6.35mmの長方形に切り出し、ASTM D2402―07に従って、71℃の温水中に2週間浸漬し、充分に吸水させた後、82℃の環境下で層間剪断強度を測定した。
180℃の温度で2時間硬化させ、厚さ6mmの樹脂硬化物を得た。この樹脂硬化物を2.7×150mmでカットし、試験片を得た。インストロン万能試験機(インストロン社製)を用い、ASTEM D5045に従って試験片を加工・実験をおこなった。ここで言う、樹脂硬化物の靱性とは、変形モード1(開口型)の臨界応力強度のことをさしている。
Claims (8)
- (A)分子中に式(1)で表されるベンゾオキサジン環を有する化合物と、
(B)エポキシ樹脂と、(C)硬化剤と、(D)靭性向上剤と、(E1)平均粒径1μm以上15μm未満のポリアミド12粉末を含み、
(A)成分及び(B)成分の含有割合が合計100質量%となるように、(A)成分65~78質量%、及び(B)成分22~35質量%を含み、(A)成分及び(B)成分の合計100質量部に対して、(C)成分5~20質量部、(D)成分3~20質量部及び(E1)成分20~30質量部含有し、(D)成分が溶解しているベンゾオキサジン樹脂組成物。 - (A)分子中に式(1)で表されるベンゾオキサジン環を有する化合物と、
(B)エポキシ樹脂と、(C)硬化剤と、(D)靭性向上剤と、(E2)平均粒径15μm以上60μm以下のポリアミド12粉末を含み、
(A)成分及び(B)成分の含有割合が合計100質量%となるように、(A)成分65~78質量%、及び(B)成分22~35質量%を含み、(A)成分及び(B)成分の合計100質量部に対して、(C)成分5~20質量部、(D)成分3~20質量部及び(E2)成分5~20質量部含有し、(D)成分が溶解しているベンゾオキサジン樹脂組成物。 - (D)靭性向上剤が、無機微粒子、有機微粒子、あるいは無機微粒子及び/又は有機微粒子を液状樹脂あるいは樹脂モノマー中に分散させたものからなる群より選択される少なくとも1種である請求項1又は2記載のベンゾオキサジン樹脂組成物。
- (B)エポキシ樹脂が、クレゾールノボラック型エポキシ樹脂、フェノールノボラック型エポキシ樹脂、ビフェニル型エポキシ樹脂、ナフタレン型エポキシ樹脂、芳香族系グリシジルエステル型エポキシ樹脂、芳香族系アミン型エポキシ樹脂、レゾルシン型エポキシ樹脂、又は脂環式エポキシ樹脂からなる群から選ばれた少なくとも1種のエポキシ樹脂である請求項1~3のいずれかに記載のベンゾオキサジン樹脂組成物。
- (C)硬化剤が、芳香族アミン、単官能フェノール、多官能フェノール化合物、又はポリフェノール化合物からなる群より選択される少なくとも1種である請求項1~4のいずれかに記載のベンゾオキサジン樹脂組成物。
- 請求項1~5のいずれかに記載のベンゾオキサジン樹脂組成物を強化繊維基材に含浸してなるプリプレグ。
- 請求項1~5のいずれかに記載のベンゾオキサジン樹脂組成物の硬化物と強化繊維基材とからなる繊維強化複合材料。
- SACMA SRM 2R-94に従い測定した衝撃後圧縮強度(CAI)が290MPa以上、ASTM D2402-07に従い測定した層間せん断強度(ILSS)が50MPa以上、ASTEM D5045に従い測定した曲げ破壊靱性が1.2MPa・m1/2以上であり、かつ前記ベンゾオキサジン樹脂組成物を180℃、2時間の条件で硬化させた硬化物のガラス転移温度が190℃以上である請求項7記載の繊維強化複合材料。
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2011
- 2011-09-30 WO PCT/JP2011/072565 patent/WO2013046434A1/ja active Application Filing
- 2011-09-30 CN CN201180075120.2A patent/CN104254566B/zh active Active
- 2011-09-30 KR KR1020147009826A patent/KR20140081817A/ko not_active Application Discontinuation
- 2011-09-30 EP EP11873064.7A patent/EP2762528B1/en active Active
- 2011-09-30 US US14/348,431 patent/US20140212658A1/en not_active Abandoned
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WO2014157101A1 (ja) * | 2013-03-29 | 2014-10-02 | Jx日鉱日石エネルギー株式会社 | プリプレグ、繊維強化複合材料及び粒子含有樹脂組成物 |
WO2014157100A1 (ja) * | 2013-03-29 | 2014-10-02 | Jx日鉱日石エネルギー株式会社 | プリプレグ、繊維強化複合材料及び粒子含有樹脂組成物 |
WO2014157097A1 (ja) * | 2013-03-29 | 2014-10-02 | Jx日鉱日石エネルギー株式会社 | プリプレグ、繊維強化複合材料及び粒子含有樹脂組成物 |
WO2014157098A1 (ja) * | 2013-03-29 | 2014-10-02 | Jx日鉱日石エネルギー株式会社 | プリプレグ、繊維強化複合材料及び粒子含有樹脂組成物 |
WO2014157099A1 (ja) * | 2013-03-29 | 2014-10-02 | Jx日鉱日石エネルギー株式会社 | 繊維強化複合材料の製造方法 |
US9745471B2 (en) | 2013-03-29 | 2017-08-29 | Jx Nippon Oil & Energy Corporation | Prepreg, fiber-reinforced composite material, and resin composition containing particles |
US10577470B2 (en) | 2013-03-29 | 2020-03-03 | Subaru Corporation | Prepreg, fiber-reinforced composite material, and resin composition containing particles |
US20160280872A1 (en) * | 2013-11-19 | 2016-09-29 | Jx Nippon Oil & Energy Corporation | Prepreg, fibre-reinforced composite material, and particle-containing resin composition |
US20160289404A1 (en) * | 2013-11-19 | 2016-10-06 | Jx Nippon Oil & Energy Corporation | Prepreg, fibre-reinforced composite material, and particle-containing resin composition |
US20160289403A1 (en) * | 2013-11-19 | 2016-10-06 | Jx Nippon Oil & Energy Corporation | Prepreg, fibre-reinforced composite material, and particle-containing resin composition |
US20160289405A1 (en) * | 2013-11-19 | 2016-10-06 | Jx Nippon Oil & Energy Corporation | Prepreg, fibre-reinforced composite material, and particle-containing resin composition |
Also Published As
Publication number | Publication date |
---|---|
CN104254566A (zh) | 2014-12-31 |
CN104254566B (zh) | 2016-03-23 |
KR20140081817A (ko) | 2014-07-01 |
US20140212658A1 (en) | 2014-07-31 |
EP2762528A1 (en) | 2014-08-06 |
EP2762528A4 (en) | 2015-06-03 |
EP2762528B1 (en) | 2020-03-11 |
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