WO2021060226A1 - エポキシ樹脂組成物および硬化物 - Google Patents
エポキシ樹脂組成物および硬化物 Download PDFInfo
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- WO2021060226A1 WO2021060226A1 PCT/JP2020/035659 JP2020035659W WO2021060226A1 WO 2021060226 A1 WO2021060226 A1 WO 2021060226A1 JP 2020035659 W JP2020035659 W JP 2020035659W WO 2021060226 A1 WO2021060226 A1 WO 2021060226A1
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- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
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- C08G18/30—Low-molecular-weight compounds
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- C08G18/30—Low-molecular-weight compounds
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- C08G18/3228—Polyamines acyclic
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- C08G18/4018—Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
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- C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G18/44—Polycarbonates
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- C08G18/48—Polyethers
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- C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
- C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
- C08G18/6633—Compounds of group C08G18/42
- C08G18/6637—Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38
- C08G18/664—Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
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- C08G18/00—Polymeric products of isocyanates or isothiocyanates
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- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
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- C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
- C08G18/6666—Compounds of group C08G18/48 or C08G18/52
- C08G18/667—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38
- C08G18/6674—Compounds of group C08G18/48 or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
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- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
- C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
- C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
- C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
- C08G18/7671—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups containing only one alkylene bisphenyl group
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- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/14—Polycondensates modified by chemical after-treatment
- C08G59/1433—Polycondensates modified by chemical after-treatment with organic low-molecular-weight compounds
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- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
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- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
- C08G59/4014—Nitrogen containing compounds
- C08G59/4021—Ureas; Thioureas; Guanidines; Dicyandiamides
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- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
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- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
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- C08L2205/035—Polymer mixtures characterised by other features containing three or more polymers in a blend containing four or more polymers in a blend
Definitions
- the present invention relates to a polyurethane-modified epoxy resin composition in which a polyurethane-modified epoxy resin is mixed with a polyurethane-unmodified epoxy resin for adjusting the polyurethane concentration and a curing agent, and a cured product thereof.
- Epoxy resin has excellent workability and can bring out various cured product properties such as high heat resistance, high insulation reliability, high rigidity, high adhesiveness, and high corrosion resistance, so it is an electrically insulating material (casting, impregnation, laminated board). , Encapsulant), matrix resin of composite materials such as CFRP, structural adhesives, heavy corrosion resistant paints, etc.
- the cured epoxy resin has low elongation at break, low fracture toughness, and low peel strength. Therefore, rubber-modified and polyurethane-modified products are used for matrix resins of composite materials and structural adhesives that require these characteristics. The above characteristics have been improved by various modifications such as.
- Patent Document 1 and Patent Document 2 polypropylene diol and isophorone diisocyanate are contained in a bisphenol A type epoxy resin containing a hydroxyl group, and the total OH group molars of NCO group, bisphenol A type epoxy resin and polypropylene diol in isophorone diisocyanate
- An epoxy resin composition obtained by blending a specific epoxy resin such as polyoxyalkylene diglycidyl ether with a polyurethane-modified epoxy resin synthesized by blending so that the ratio is NCO / OH 1.0 has shear strength and peel strength.
- Patent Document 3 a specific diol compound and diphenylmethane diisocyanate are charged in a bisphenol A type epoxy resin and reacted to obtain a urethane prepolymer, and then a chain length extender 1,4-butanediol is charged to make polyurethane. It is disclosed that the resin composition containing the urethane-modified epoxy resin obtained is a cured product having a high fracture toughness value useful for electrical and electronic applications and building material applications.
- the present inventors have disclosed a urethane-modified epoxy resin in Patent Document 4, and the urethane-modified epoxy resin is sufficiently improved in impact resistance with a certain curing agent in the composition. There was no problem.
- Patent Document 5 has been studied as an adhesive having enhanced flexibility and toughness by using a polycarbonate polyol. Here, lowering the elastic modulus, flexibly relaxing stress, and increasing toughness are described as effects, but no data on toughness are shown, only strength and elongation are shown.
- Patent Document 6 a study is made to apply a polycarbonate diol to a urethane-modified epoxy resin, but the effect of lowering the breaking toughness by using the polycarbonate diol is described, and it is described in polytetramethylene glycol and polypropylene glycol. It has been shown that high toughness cannot be obtained with polycarbonate diols, which are more rigid in structure.
- the present invention has a glass transition temperature of 110 ° C. or higher in order to improve fatigue resistance, peel strength, impact resistance, and compressive strength of cast materials, composite materials, and structural adhesives, and to maintain heat resistance of cured products.
- a novel polyurethane-modified epoxy resin composition capable of having an Izot impact strength value (JISK7110; no notch) of 30 kJ / m 2 or more, an elastic modulus of 2.5 GPa or more, and a breaking toughness of 2.0 MPa ⁇ m 0.5 or more. It is intended to provide a cured product.
- (A) A polyurethane-modified epoxy resin having a polycarbonate structure in the molecule and having a urethane modification rate of 20 to 60% by weight.
- (B) Polyurethane unmodified epoxy resin liquid at 30 ° C.
- (C) A bisphenol-type solid epoxy resin having a glass transition temperature or melting point of 50 ° C. or higher, and (D) an amine-based curing agent which is dicyandiamide or a derivative thereof.
- the epoxy resin composition is characterized by containing 50.0% by weight and 0.1 to 50.0% by weight of the component (C).
- the polycarbonate structure contained in the component (A) may include a structural unit represented by the general formula (1).
- R is an alkylene group having 1 to 20 carbon atoms independently, and n is a number of 1 to 50 carbon atoms.
- Mw weight average molecular weight
- the component (A) is represented by the following formula (2), and a bisphenol epoxy resin (a) having an epoxy equivalent of 150 to 200 g / eq and a hydroxyl group equivalent of 2000 to 3000 g / eq is used as a medium high molecular weight polyol compound (b). It is desirable that the polyurethane-modified epoxy resin is modified with a polycarbonate diol compound (b-2), a polyisocyanate compound (c), and a low molecular weight polyol compound (d) having a number average molecular weight of less than 200 as a chain length extender.
- the epoxy resin (a) is used in an amount of 50 to 80% by weight based on the total amount of the components (a), (b), (b-2), (c) and (d), and the polycarbonate diol (
- the epoxy resin (a) and the components (b), (b-2) are used in an amount of b-2) which is 20 to 55% by weight based on the total amount of the components (b) and (b-2).
- the present invention is an epoxy resin cured product characterized in that the above epoxy resin composition is cured. It is desirable that the cured epoxy resin has a glass transition temperature of 110 ° C. or higher, an Izod impact strength value of 30 kJ / m 2 or higher, an elastic modulus of 2.5 GPa or higher, and a fracture toughness of 2.0 MPa ⁇ m 0.5 or higher.
- the epoxy resin composition of the present invention can improve both the strength, breaking toughness and impact resistance of the cured product, and can also suppress a decrease in the glass transition temperature. Therefore, the resin composition and the cured product can be used for adhesives and coated. It is suitable for materials, electrical and electronic materials, matrix resins for composite materials, and the like.
- the epoxy resin composition of the present invention is (A) a polyurethane-modified epoxy resin having a polycarbonate structure in the molecule and a urethane modification rate of 20 to 60% by weight, and (B) a polyurethane unmodified epoxy resin liquid at 30 ° C. , (C) A solid epoxy resin having a bisphenol structure having a glass transition temperature or a melting point of 50 ° C. or higher, and (D) an amine-based curing agent which is dicyandiamide or a derivative thereof are contained as essential components.
- each of these components is also referred to as a polyurethane-modified epoxy resin, a liquid epoxy resin, a solid epoxy resin, an amine-based curing agent, or a component (A), a component (B), a component (C), and a component (D), respectively.
- a component (A), a component (B), a component (C), and a component (D), respectively a component (A), a component (B), a component (C), and a component (D), respectively.
- each component will be described.
- the component (A) is preferably a polyurethane-modified epoxy resin having a polycarbonate structure in the molecule, and the weight concentration of the polyurethane component is 20.0 to 60.0% by weight. Is.
- the polyurethane-modified epoxy resin is prepared by reacting the epoxy resin (a) with a medium-high molecular weight polyol compound (b), a polycarbonate diol compound (b-2), a polyisocyanate compound (c), and a low molecular weight polyol compound (d). Can be manufactured.
- the epoxy resin (a), the medium high molecular weight polyol compound (b), the polycarbonate diol compound (b-2), the polyisocyanate compound (c) and the low molecular weight polyol compound (d) are added to the components (a) and (b), respectively. ), (B-2), (c) and (d).
- the polyurethane constituent is a component excluding the epoxy resin (a) as a raw material, that is, a polyol compound (b), a polycarbonate diol compound (b-2), a polyisocyanate compound (c), and a low molecular weight polyol compound (d).
- the urethane modification rate refers to the ratio of the total of these polyurethane components to the total weight of the polyurethane-modified epoxy resin.
- the components (b), (b-2), and (d) are all polyol compounds, but the component (b) has a number average molecular weight of 200 or more, and the component (d) has a number average molecular weight of 200. It differs in that it is less than. Further, the compound corresponding to the component (b-2) is treated as a compound of the component (b-2) even if it may also correspond to the component (b) or (d), and is treated as a compound of the component (b-2) and the component (b) or (d). ) Is not a compound.
- the polycarbonate diol compound (b-2) may be a medium high molecular weight polyol compound, but the effect of the present invention can be exhibited particularly by including this structure.
- a compound having a structure such as aromatic, aliphatic or alicyclic can be used as long as it is a diol having a carbonate bond in the molecule.
- a carbonic acid derivative and an aliphatic polyol can be used. Those obtained by an esterification reaction can be used.
- the polycarbonate diol compound (b-2) is preferably an aliphatic polycarbonate diol compound represented by the following formula (3).
- R is an alkylene group having 1 to 20 carbon atoms independently, and n is a number of 1 to 50 carbon atoms.
- the polycarbonate diol compound (b-2) preferably has a number average molecular weight of about 800 to 3000 in consideration of flexibility and compatibility with other resins.
- the medium high molecular weight polyol compound (b) a compound having a number average molecular weight of 200 or more and excluding the polycarbonate diol compound (b-2) is used.
- the OH group may be a secondary hydroxyl group, but if it is a primary hydroxyl group, the reactivity is excellent.
- R 2 is an H or methyl group
- b1, b2, b3 are independently numbers 1 to 50
- c is a number 0 or 1.
- R 2 is an H or methyl group
- d1, d2, e1, e2 are independently numbers 1 to 20.
- h1 and h2 are independently numbers from 1 to 20, and i is a number from 1 to 50.
- j1, j2, and j3 are independently numbers from 1 to 20, and k1 and k2 are independently numbers from 1 to 50.
- l1, l2, l3, l4, l5 are independently numbers from 1 to 20, and m1 and m2 are independently numbers from 1 to 50.
- o1, o2, o3, o4 are independently numbers 1 to 20.
- the medium high molecular weight polyol compound (b) preferably has a number average molecular weight of 200 or more, has a molecular structure according to any one of the above formulas (4) to (12), and has excellent compatibility with the epoxy resin (a).
- polyethylene glycols and polypropylene glycols in which ethylene oxide or propylene oxide is ring-opened and weight-added to a polyhydric alcohol such as ethylene glycol or glycerin can be exemplified.
- c is 0 and R 2 is a methyl group.
- Polypropylene glycol represented by the formula (13) is preferable from the viewpoint of easy availability and a good balance between price and characteristics.
- the number of OH groups in the polyol compound (b) may be 2 or more, but is preferably 2. (Here, b1 and b2 are independently numbers from 1 to 50.)
- polypropylene glycol having a number average molecular weight of 1500 to 5000, preferably 2000 to 3000 does not thicken or semi-solidify the polyurethane-modified epoxy resin composition, and has good tackiness and adhesive surface of this composition. It is preferable from the viewpoint of ensuring good followability, castability, and good impregnation property into carbon fiber and glass fiber.
- the epoxy resin (a) is preferably liquid at room temperature, and from this viewpoint, the epoxy equivalent is preferably 200 g / eq or less.
- the epoxy equivalent is preferably 200 g / eq or less.
- it is an epoxy resin having an epoxy equivalent of 150 to 200 g / eq and a hydroxyl group equivalent of 2000 to 3000 g / eq.
- a secondary hydroxyl group-containing bisphenol epoxy resin represented by the above formula (2) and having an epoxy equivalent of 150 to 200 g / eq and a hydroxyl group equivalent of 2000 to 2600 g / eq is preferable.
- R 1 is independently an H or an alkyl group
- a is a number from 0 to 10.
- the number of carbon atoms is preferably in the range of 1 to 3, and more preferably 1.
- a particularly preferable epoxy resin (a) is a bisphenol A type epoxy resin represented by the formula (14) or a bisphenol F type epoxy resin represented by the formula (15).
- a1 and a2 are numbers from 0 to 10, but when they have a molecular weight distribution, the average value (number average value) may satisfy the above range.
- the a1 and a2 are determined so as to satisfy the epoxy equivalent and the hydroxyl group equivalent.
- Polyisocyanate compound (c) is represented by the formula (16), R 4 is what is preferably a divalent group selected from the formulas (16a) ⁇ (16f). Of these, those having excellent compatibility with the epoxy resin (a) are preferable. Specific examples thereof include toluene diisocyanate (TDI), 4,4'-diphenylmethane diisocyanate (MDI), xylylene diisocyanate (XDI), hydrogenated xylylene diisocyanate (HXDI), isophorone diisocyanate (IPDI), naphthalene diisocyanate and the like.
- TDI toluene diisocyanate
- MDI 4,4'-diphenylmethane diisocyanate
- XDI xylylene diisocyanate
- HXDI hydrogenated xylylene diisocyanate
- IPDI isophorone diisocyanate
- MDI represented by the formula (17) is preferable from the viewpoints of low molecular weight, no thickening, low cost, and safety.
- the number of NCO groups in the polyisocyanate compound (c) may be 2 or more, but is preferably 2.
- R 4 is a divalent group selected from the formulas 16a to 16f.
- the low molecular weight polyol compound (d) is a polyol compound having a number average molecular weight of less than 200. It is used as a chain length extender. Preferably, it is a diol compound having two primary hydroxyl groups represented by the formula (18). (Here, R 5 is an alkylene group represented by the formula 18a, and g is a number from 1 to 10.)
- the low molecular weight polyol compound (d) include polyhydric alcohols such as 1,4-butanediol and 1,6-pentanediol. Among these, 1,4-butanediol is more preferable from the viewpoint of easy availability and a good balance between price and characteristics.
- each component (a), (b), (b-2), (c) and (d) will be described with a reaction mechanism.
- Each component can be used alone or in admixture of two or more.
- the OH group of the polyol compound (b) and the polycarbonate diol compound (b-2) is a primary OH group
- the epoxy resin (a) the polyol compound (b), the polycarbonate diol compound (b-2) and
- the polyisocyanate compound (c) is charged and reacted, the primary OH group of these compounds reacts preferentially with the NCO group of the polyisocyanate compound (c).
- the primary OH group in the polyol compound (b) and the polycarbonate diol compound (b-2) reacts first with the NCO group in the polyisocyanate compound (c), and the urethane prepolymer at the end of the NCO group reacts first.
- (P1) is generated.
- the urethane prepolymer (P2) in which epoxy resin is added to both ends is mainly produced because the molar ratio of NCO groups is large and the epoxy resin is also used in a large excess.
- the number of moles of the OH group and the NCO group is the polyol compound (b) and the polycarbonate diol compound (b).
- the ratio of the number of moles of -2) to the number of moles of the polyisocyanate compound (c) is consistent.
- the molar ratio of NCO group / OH group is preferably 1.5 to 6.
- the components (b), (b-2) and (c) are bifunctional, the molar ratio of these charges or (c) / [(b) + (b-2)] is 1.5 to 6. Is preferable.
- a urethane prepolymer having both terminal isocyanate groups can be obtained.
- a urethane polymer having a single-ended isocyanate or a urethane polymer having an OH group at the end is likely to be produced.
- the low molecular weight polyol compound (d) is subjected to molars of NCO groups in the urethane prepolymer (P) and OH groups in the low molecular weight polyol compound (d).
- the polyurethane-modified epoxy resin used in the present invention can be obtained by charging so that the ratio (P): (d) is in the range of 0.9: 1 to 1: 0.9 and carrying out the polyurethane-forming reaction.
- the low molecular weight polyol compound (d) it is preferable to use an amount in which the NCO group at the end of the urethane prepolymer (P) and the OH group of the low molecular weight polyol compound (d) are approximately equal molars. That is, since the polyol compound (b), the polycarbonate diol compound (b-2), and the low molecular weight polyol compound (d) have an OH group, and the polyisocyanate compound (c) has an NCO group, (b) + (b). -2) It is preferable that the number of moles of OH groups (B) of + (d) and the number of moles of NCO groups (C) in (c) are substantially the same. It is preferably in the range of 0.9: 1 to 1: 0.9. The closer the ratio of the number of moles of OH groups to the number of moles of NCO groups is to 1, the higher the molecular weight of the produced polyurethane.
- the epoxy resin (a) is used as a polyol compound (b), a polycarbonate diol compound (b-2), a polyisocyanate compound (c), and a low molecular weight polyol compound ( Use of 50 to 80% by weight based on the total amount of d) and 20 to 55% by weight of the polycarbonate diol (b-2) based on the total amount of the component (b) and the component (b-2). In an amount, the reaction is carried out in the presence of the epoxy resin (a) (reaction 1).
- reaction 1 the reaction of the polyol compound (b) and the polycarbonate diol compound (b-2) with the polyisocyanate compound (c) occurs preferentially to produce a urethane prepolymer (P1), and then the urethane prepolymer (P1).
- reaction temperature is in the range of 80 to 150 ° C. and the reaction time is in the range of 1 to 5 hours.
- the molar ratio (P): (d) of the NCO group in the urethane prepolymer (P) and the OH group in the low molecular weight polyol compound (d) is in the range of 0.9: 1 to 1: 0.9.
- reaction temperature of reaction 2 is preferably in the range of 80 to 150 ° C. and the reaction time is preferably in the range of 1 to 5 h, which is the reaction between the NCO group and the OH group in the low molecular weight polyol compound (d). Therefore, conditions milder than reaction 1 are sufficient.
- a catalyst can be used if necessary.
- This catalyst is used for the purpose of sufficiently completing the formation of urethane bonds, and examples thereof include amine compounds such as ethylenediamine, tin compounds, and zinc compounds.
- the urethane prepolymer (P1) which is slightly present and has NCO at both ends or one end, reacts with the low molecular weight polyol compound (d) to extend the chain length and become polyurethane, and both ends are epoxy resin (Poxy resin (P1).
- N 1 or more in the epoxy resin (a) is added to one end of the polymer (P), the other end is a resin component that is an NCO group, and both ends of the urethane prepolymer (P) are NCO.
- It is a mixture of the base resin component and the n 0 component in the epoxy resin (a)
- the epoxy equivalent is in the range of 180 to 1000 g / eq
- the viscosity at 120 ° C. is in the range of 0.1 to 20 Pa ⁇ s. Is preferable.
- reaction formula for obtaining the polyurethane-modified epoxy resin (A) used in the composition of the present invention is shown below.
- a bisphenol epoxy resin a
- b medium high molecular weight polyol compound
- c polyisocyanate compound
- the following formula 20 schematically describes the urethane polymer step (polyurethane step) as the reaction 2.
- the epoxy resin composition of the present invention comprises the above-mentioned polyurethane-modified epoxy resin (A), a polyurethane-unmodified liquid epoxy resin (B) as a polyurethane concentration adjusting agent, a compatibility and viscosity adjusting material, a resin sheet and a prepreg. It can be obtained by blending a bisphenol type solid epoxy resin (C) having a glass transition temperature or a melting point of 50 ° C. or higher and an amine-based curing agent (D) as an agent for improving tackiness in the above state.
- A polyurethane-modified epoxy resin
- B polyurethane-unmodified liquid epoxy resin
- D amine-based curing agent
- the resin composition of the present invention contains other epoxy resins (component E), curing accelerator (F), and inorganic fillers such as calcium carbonate, talc, and titanium dioxide for fine adjustment of viscosity and Tg, if necessary. Can be blended as a bulking material or a reinforcing material.
- component E epoxy resins
- F curing accelerator
- inorganic fillers such as calcium carbonate, talc, and titanium dioxide for fine adjustment of viscosity and Tg, if necessary.
- the liquid epoxy resin (B) is not particularly limited as long as it is not polyurethane-modified and is liquid at 30 ° C., but bisphenol A type epoxy resin or bisphenol F type epoxy resin is easily available. It is preferable because of the good balance between price and characteristics.
- the polyurethane concentration in the epoxy resin composition can be increased or decreased.
- (a) to (d), (B), (C), and (D) are the weights of the corresponding essential components used.
- other components such as other epoxy resin (E) and curing accelerator (F) are blended in addition to the essential components, these other components are added to the denominator.
- the cured product characteristics such as bending strain, impact resistance, and glass transition temperature change.
- the bending strain of the cured product generally tends to increase, and the impact resistance tends to increase.
- the epoxy resin composition of the present invention contains a bisphenol type solid epoxy resin (C) having a glass transition temperature or a melting point of 50 ° C. or higher.
- a solid epoxy resin (C) having a glass transition temperature or a melting point of 50 ° C. or higher.
- a solid epoxy resin (C) it can be used as long as the glass transition temperature or the melting point is 50 ° C. or higher.
- a high molecular weight type of bisphenol type epoxy resin is useful, and other solid bisphenol F type. Examples thereof include epoxy resins, biphenyl-type epoxy resins, dicyclopentadiene-type epoxy resins, and modified epoxy resins thereof, or phenoxy resins.
- When used for adjusting the viscosity of the resin composition or increasing Tg it is preferably 0.1 to 50% by weight based on the total weight of the composition.
- the component (A) is 20.0 to 50.0% by weight, the component (B) is 10 to 40% by weight, and the component (the component (B) is 10 to 40% by weight, based on the total of the components (A) to (D).
- C) is preferably contained in an amount of 0.1 to 50.0% by weight. If the component (A) is less than 20.0% by weight, the sea-island structure is not formed neatly and sufficient impact strength cannot be obtained, and if it exceeds 50.0% by weight, the phase-separated state mutually invades from the sea-island structure. The structure may be similar to that of the above, and sufficient impact strength may not be obtained.
- the component (C) is appropriately designed to adjust the viscosity in order to suppress the resin flow during molding while maintaining the impregnation property and fluidity of the resin. If it exceeds 50.0% by weight, the viscosity increases too much, which may cause inconvenience in handling.
- the epoxy resin composition of the present invention preferably has an initial viscosity of 100 to 2000 Pa ⁇ s. More preferably, the initial viscosity is 1100-1500 Pa ⁇ s.
- dicyandiamide (DICY) or a derivative thereof is used because it can be liquefied into one liquid with excellent storage stability and can be easily obtained.
- the amount of the curing agent (D) is the number of moles of epoxy groups of the total epoxy resin including the polyurethane-modified epoxy resin and the polyurethane-unmodified epoxy resin (B) and the number of moles of active hydrogen groups of DICY.
- the ratio is preferably set in the range of 1: 0.3 to 1: 1.2, preferably 1: 0.9 to 1: 1.1 from the viewpoint of cured product characteristics.
- a trifunctional or higher functional epoxy resin can be used as another epoxy resin (E) in order to finely adjust the viscosity and increase Tg.
- E another epoxy resin
- a polyfunctional epoxy resin is used, the crosslink density increases, the phase separation state changes, and the fracture toughness is lost. Therefore, it is preferably 0.1 to 10% by weight based on the total weight of the composition.
- Examples of the trifunctional or higher functional epoxy resin include phenol novolac type epoxy resin, cresol novolac type epoxy resin, glycidylamine type epoxy resin such as tetraglycidyldiaminodiphenylmethane, tetrakis (glycidyloxyphenyl) ethane and tris (glycidyloxyphenyl).
- Examples thereof include glycidyl phenyl ether type epoxy resin such as methane, and glycidyl amine type and glycidyl phenyl ether type epoxy resin such as triglycidyl aminophenol.
- an epoxy resin obtained by modifying these epoxy resins, a bromized epoxy resin obtained by bromizing these epoxy resins, and the like can be mentioned.
- the epoxy resin composition of the present invention can further contain a curing accelerator (F).
- a curing accelerator (F) examples include crystalline imidazole compounds such as 2,4-diamino-6- [2'-methylimidazolyl- (1')] -ethyl-s-triazine isocyanuric acid addition salt (2MA-OK).
- Urea compounds such as 3- (3,4-dichlorophenyl) -1,1-dimethylurea (DCMU) can be used.
- the blending amount of the curing accelerator (F) is in the range of 0.1 to 5 wt% with respect to the total of the total epoxy resin including the polyurethane-modified epoxy resin and the polyurethane-unmodified liquid epoxy resin (B) and the curing agent (D). Is preferable.
- the epoxy resin composition of the present invention does not impair processability such as tackiness, followability to an adhesive surface, castability to a mold, and impregnation property into carbon fibers, glass fibers and their woven fabrics.
- the cured product of the epoxy resin composition of the present invention is obtained after casting the epoxy resin composition into a mold, applying it to an adherend as an adhesive and adhering it, or applying it as a paint to an object to be coated.
- it can be obtained by impregnating carbon fibers, glass fibers and their woven fabrics, heating them to a temperature of 80 ° C. to 200 ° C., and holding them for several hours.
- the cured product of the epoxy resin composition of the present invention has an Izod impact value (without notch) of 30 kJ / m 2 or more, a glass transition temperature of 110 ° C. or more, an elastic modulus of 2.5 GPa or more, and fracture toughness. It can be 2.0 MPa ⁇ m0.5 or more.
- Viscosity The viscosity of the pre-cured resin composition at 40 ° C. was measured with an E-type viscometer.
- Glass transition temperature (Tg) The glass transition temperature (Tg) is derived from the peak temperature of the tan ⁇ curve of the cured product test piece under the condition of a temperature rise rate of 2 ° C./min using a dynamic viscoelasticity measuring device. did.
- Izod Impact Strength The measurement was performed at room temperature of 23 ° C. without a notch according to the Izod test method of JIS K7110.
- Tackability The pre-cured resin composition is melted at 60-80 ° C. and applied with a bar coater to a thickness of 100 g / m 2 on a substrate such as a paper pattern, and a polyethylene film having a thickness of 40 ⁇ m is used as a cover material. It was judged whether or not it could be brought into close contact with each other and peeled off at 25 ° C. without resin residue.
- Fracture toughness A cured product formed by casting a mold into the shape of JIS K 6911 is used as a test piece, and a test is performed using a universal testing machine at a room temperature of 23 ° C. and a crosshead speed of 0.5 mm / min. Was done. The notch (notch) in the test piece before the test was created by applying the razor blade to the test piece and giving an impact to the razor blade with a hammer.
- Epoxy resin (a) is "Epototo YDF-170”
- polyol (b) is "Adekapolyester P-2000”
- polycarbonate diol (b-2) is “Duranol T5652”
- polyisocyanate (c) is "Cosmonate PH”.
- 1,4-Butanediol was used as the low molecular weight polyol (d). The amounts used are shown in Table 1.
- Epototo YDF-170, Adekapolyether P-2000, and Duranol T5652 were placed in a 1000 ml four-necked separable flask equipped with a nitrogen introduction tube, a stirrer, and a temperature controller, and stirred and mixed at room temperature for 15 minutes.
- cosmonate PH was added and reacted at 120 ° C. for 2 hours (reaction 1: urethane prepolymer step, this reaction product is referred to as a primary reaction product).
- 1,4-butanediol was added and reacted at 120 ° C.
- reaction 2 polyurethane step
- a polyurethane-modified bisphenol F type epoxy resin (resin 1).
- the epoxy resin (a) was charged so as to be 72% by weight with respect to 100% by weight of the product of Reaction 2.
- the molar ratio of OH group to NCO group (b) + (b-2): (c) was 1: 2.4.
- the NCO group in the primary reaction product: OH group in (d) was set to 1. The completion of the reaction was confirmed by IR measurement by the disappearance of the absorption spectrum of the NCO group.
- Synthesis Examples 2 to 10 The reaction was carried out in the same procedure as in Synthesis Example 1 except that the raw material preparation composition was as shown in Tables 1 and 2, and a polyurethane-modified bisphenol F type epoxy resin (resins 2 to 10; the resin number corresponds to the synthesis example number) was used. Obtained.
- Example 1 As the polyurethane-modified epoxy resin (A), the polyurethane-modified bisphenol F type epoxy resin (resin 1) obtained in Synthesis Example 1, as the polyurethane unmodified liquid epoxy resin (B), Epototo YD-128, and the bisphenol type solid epoxy resin (C). YD-014 (C-1) or YD-019 (C-2), KDPN-1020 as the other epoxy resin (E), dicyandiamide as the curing agent (D), and 2MA-OK as the curing accelerator (F).
- the size of the test piece for bending test and the size of the test piece for fracture toughness are 100 mmL x 10 mmW x 4 mmt, and the size of the test piece for DMA test is 100 mmL x 10 mmW x 1 mmt. It was cut and used. The castability at this time was at a level at which casting was sufficiently possible with a margin. Next, a mold in which the resin was cast was placed in a hot air oven and heat-cured at 130 ° C. for 50 minutes and further at 150 ° C. for 50 minutes to prepare an epoxy resin cured product test piece. The test results using this test piece are shown in Table 3.
- the blending amount is g.
- ⁇ indicates good and ⁇ indicates defective.
- compositions containing the urethane-modified epoxy resins of Examples 1 to 7 had both high heat resistance, high elasticity, high fracture toughness, and high impact strength as compared with Comparative Examples 1 to 5.
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Abstract
Description
(A)分子内にポリカーボネート構造を有し、ウレタン変性率が20~60重量%であるポリウレタン変性エポキシ樹脂、
(B)30℃で液状のポリウレタン未変性エポキシ樹脂、
(C)ガラス転移温度または融点が50℃以上のビスフェノール型の固形エポキシ樹脂、及び
(D)ジシアンジアミドまたはその誘導体であるアミン系硬化剤、
を必須成分とするエポキシ樹脂組成物であって、成分(A)~(D)の合計に対し、成分(A)を20.0~50.0重量%、成分(B)を0.1~50.0重量%、成分(C)を0.1~50.0重量%含有することを特徴とするエポキシ樹脂組成物である。
(ここで、Rはそれぞれ独立に、炭素数1~20のアルキレン基であり、nは1~50の数である。)
また、重量平均分子量(Mw)が10,000以上50,000以下のポリウレタン変性エポキシ樹脂であることがよい。
そして、その製造方法としては、上記成分(a)、(b)、(b‐2)、(c)を反応させたのち、成分(d)を反応させることが望ましい。
(ここで、R1はそれぞれ独立に、H又はアルキル基であり、aは0~10の数である。)
このエポキシ樹脂硬化物は、ガラス転移温度が110℃以上、アイゾット衝撃強度値が30kJ/m2以上、弾性率2.5GPa以上、破壊靭性2.0MPa・m0.5以上であることが望ましい。
ポリウレタン構成成分とは、原料としてのエポキシ樹脂(a)を除く成分、すなわち、ポリオール化合物(b)、ポリカーボネートジオール化合物(b-2)、ポリイソシアネート化合物(c)および低分子量ポリオール化合物(d)であり、ウレタン変性率とは、ポリウレタン変性エポキシ樹脂全体の重量に対するこれらのポリウレタン構成成分の合計の比をいう。
ポリカーボネートジオール化合物(b-2)としては、分子内にカーボネート結合を有するジオールであれば芳香族、脂肪族、脂環等の構造を有する化合物が使用でき、例えば、炭酸誘導体と脂肪族ポリオールとをエステル化反応して得られるもの等を使用することができる。具体的には、エチレングリコール、1,2-プロパンジオール、1,3-プロパンジオール、1,4-ブタンジオール、1,6-ヘキサンジール、ジエチレングリコール、ポリエチレングリコール、ポリプロピレングリコール又はポリテトラメチレングリコール(PTMG)等のようなジオールと、ジメチルカーボネートやジフェニルカーボネートやホスゲン等との反応生成物などが挙げられる。これらは単独使用でも2種以上を併用してもよい。市販のものとしては、宇部興産株式会社製UH-100、UH-200、UH-300や旭化成株式会社製T5650J、T5651、T5652、G3452、T4691,T4692、G4672、T4671などが挙げられる。
(ここで、Rはそれぞれ独立に、炭素数1~20のアルキレン基であり、nは1~50の数である。)
このような化合物を使用することで、上記式(1)の構造をポリウレタン変性エポキシ樹脂中に導入することができる。この化合物の分子量や結晶性、極性、構造などによってポリウレタン変性エポキシ樹脂や組成物としたときの物性が変化する。ポリカーボネートジオール化合物(b-2)は、柔軟性や他の樹脂との相溶性などを踏まえると数平均分子量が800~3000くらいのものが特に好ましい。
(ここで、R2はH又はメチル基であり、b1,b2,b3は独立に1~50の数であり、cは0もしくは1の数である。)
(ここで、R2はH又はメチル基であり、d1,d2,e1,e2は独立に1~20の数である。)
(ここで、h1,h2は独立に1~20の数であり、iは1~50の数である。)
(ここで、j1,j2,j3は独立に1~20の数であり、k1,k2は独立に1~50の数である。)
(ここで、l1,l2,l3,l4,l5は独立に1~20の数であり、m1,m2は独立に1~50の数である。)
(ここで、o1,o2,o3,o4は独立に1~20の数である。)
式中、R1はそれぞれ独立に、H又はアルキル基であり、aは0~10の数である。アルキル基である場合、炭素数は1~3の範囲が好ましく、1がより好ましい。
式中、a1、a2は0~10の数であるが、分子量分布を有するときは平均値(数平均値)が上記範囲を満足することがよい。このa1、a2は上記エポキシ当量と水酸基当量を満足するように定められる。
具体的には例えば、トルエンジイソシアネート(TDI)、4,4’-ジフェニルメタンジイソシアネート(MDI)、キシリレンジイソシアネート(XDI)、水素化キシリレンジイソシアネート(HXDI)、イソホロンジイソシアネート(IPDI)、ナフタレンジイソシアネート等を挙げることができるが、低分子量で増粘性がなく低価格、安全性などの観点から式(17)で示されるMDIが好ましい。ポリイソシアネート化合物(c)のNCO基の数は2以上であればよいが、2であることが好ましい。
(ここで、R4は式16a~16fから選ばれる2価の基である。)
一方、ポリオール化合物(b)及びポリカーボネートジオール化合物(b-2)のOH基が1級OH基である場合は、エポキシ樹脂(a)、ポリオール化合物(b)、ポリカーボネートジオール化合物(b-2)およびポリイソシアネート化合物(c)を仕込んで反応させたとき、これらの化合物の1級OH基とポリイソシアネート化合物(c)のNCO基が優先的に反応する。
NCO基/OH基のモル比は、1.5~6が好ましい。成分(b)、(b-2)と(c)が2官能である場合は、これらの仕込みモル比又は(c)/[(b)+(b-2)]は、1.5~6が好ましい。
上記モル比を大きく、すなわちポリイソシアネート化合物(c)を過剰とすることで、より多くの両末端イソシアネート基のウレタンプレポリマーを得ることができる。上記モル比が低く1.0に近いほど、生成するウレタンプレポリマーの分子量が過度に増大して粘度が高くなり過ぎる。また、片末端イソシアネートのウレタンポリマーあるいは末端がOH基のウレタンポリマーが生成しやすくなる。一方、モル比が高くなり過ぎると生成するウレタンプレポリマーの分子量が極めて小さくなり過ぎ、マトリックス樹脂への相溶性が大きくなるため相分離構造が曖昧になり、改質効果が十分発揮できなくなる可能性が生じて好ましくない。
上記のようにNCO基のモル比をより過剰とすることにより、より両末端が変性されたウレタンプレポリマーが生成され、これによりさらに両末端がn=1以上のエポキシ樹脂が付加したウレタンプレポリマー(P2)が得られる。そのため、エポキシ樹脂硬化時はこれらウレタンプレポリマー(P2)が架橋部分に確実に導入されやすくなるため、少量で靱性の向上につながるものと考えられる。
すなわち、本発明で使用するポリウレタン変性エポキシ樹脂は、主にウレタンプレポリマー(P)の両末端にエポキシ樹脂(a)中のn=1以上体が付加した樹脂成分、少量または微量成分としてウレタンプレポリマー(P)の一方の片末端にエポキシ樹脂(a)中のn=1以上体が付加し、もう一方の片末端はNCO基である樹脂成分、ウレタンプレポリマー(P)の両末端がNCO基である樹脂成分およびエポキシ樹脂(a)中のn=0体成分の混合物であり、エポキシ当量は180~1000g/eqの範囲、120℃における粘度は0.1~20Pa・sの範囲であることが好ましい。
こうしてほぼすべてのポリウレタンは、両末端にn=1体エポキシ樹脂が付加したウレタンプレポリマー(S)と同じく両末端にn=1体エポキシ樹脂が付加した低分子ウレタンポリマー(A)およびn=0体エポキシ樹脂との混合物となり、ほぼすべてのウレタンがエポキシ樹脂で変性されたものが生成していると考えられる。
本発明の樹脂組成物は、必要に応じて、粘度やTgの微調整のためそのほかのエポキシ樹脂(成分E)、硬化促進剤(F)、さらには炭酸カルシウム、タルク、二酸化チタン等の無機フィラーを増量材、補強材として配合できる。
ポリウレタン濃度={(b)+(b-2)+(c)+(d)}×100/{(a)+(b)+(b-2)+(c)+(d)+(B)+(C)+(D)}
ここで、(a)~(d)、(B)、(C)、(D)は、対応する各必須成分の使用重量である。なお、必須成分に加えてその他の成分、例えばそのほかのエポキシ樹脂(E)、硬化促進剤(F)などを配合する場合、これらの他成分が分母に加算される。
このような固形エポキシ樹脂(C)としては、ガラス転移温度または融点が50℃以上であれば使用できるが、例えば、ビスフェノール型エポキシ樹脂の高分子量タイプのものが有用で、そのほか固形のビスフェノールF型エポキシ樹脂、ビフェニル型エポキシ樹脂、ジシクロぺンタジエン型エポキシ樹脂、さらにはこれらを変性したエポキシ樹脂等、またはフェノキシ樹脂が挙げられる。樹脂組成物の粘度調整やTgを上げたりするために使用する際は、全組成物重量に対して0.1~50重量%にするのが好ましい。
成分(A)が20.0重量%未満であると、海島構造がきれいに形成されず十分な衝撃強度が得られない、また50.0重量%を超えると、相分離状態が海島構造から相互侵入したような構造になり、同じく十分な衝撃強度が得られないことがある。成分(C)については樹脂の含浸性や流動性を維持しつつ成型時の樹脂流れを抑制するために適宜粘度調整のために設計される。50.0重量%を超えると粘度が上がりすぎるため取扱いに不都合が生じることがある。
本発明のエポキシ樹脂組成物は、初期粘度が100~2000Pa・sであるものが好適である。より好ましくは初期粘度が1100~1500Pa・sである。
実施例中に示した特性の評価方法は、次の通りである。
(2)エポキシ当量: JIS K 7236 に従って定量した。
(3)水酸基当量: ジメチルホルムアミド25mlを200mlガラス栓付三角フラスコにとり、水酸基11mg/当量以下を含む試料を精秤して加え溶解させる。1mol/L-フェニルイソシアネートトルエン溶液20mlとジブチルスズマレート触媒溶液1mlとをそれぞれピペットで加え、よく振り混ぜて混合し、密栓して30~60分間反応させる。反応終了後2mol/L-ジブチルアミントルエン溶液20mlを加えよく振り混ぜて混合し、15分間放置して過剰のフェニルイソシアネートと反応させる。次に、メチルセロソルブ30mlとブロムクレゾールグリーン指示薬0.5mlとを加え、過剰のアミンを標定済の過塩素酸メチルセロソルブ溶液で滴定する。指示薬は青から緑さらに黄色へと変化するので、黄色になった最初の点を終点とし、以下の式i、式iiを用いて水酸基当量を求めた。
水酸基当量(g/eq)=(1000×W)/C(S-B)・・・(i)
C:過塩素酸メチルセロソルブ溶液の濃度 mol/L
W:試料量(g)
S:過塩素酸メチルセロソルブ溶液の滴定量(ml)
B:滴定の際のブランクテストに要した過塩素酸メチルセロソルブ溶液の滴定量(ml)
C=(1000×w)/{121×(s-b)}・・・(ii)
w:標定のために秤取したトリス-(ハイドロキシメチル)-アミノメタンの採取量(g)
s:トリス-(ハイドロキシメチル)-アミノメタンの滴定に要した過塩素酸メチルセロソルブ溶液の滴定量(ml)
b:標定の際のブランクテストに要した過塩素酸メチルセロソルブ溶液の滴定量(ml)
(5)ガラス転移温度(Tg):硬化物試験片を、昇温速度2℃/分の条件下、動的粘弾性測定装置を用いてtanδ曲線のピーク温度からガラス転移温度(Tg)を導出した。
(6)曲げ試験: JIS K 6911の形状に金型注型によって成形した硬化物を試験片とし、万能試験機を用いて、室温23℃下、クロスヘッドスピード1mm/分の条件で曲げ試験を行い、曲げ強度、曲げ歪み、曲げ弾性率をおのおの測定した。
(7)アイゾット衝撃強度:JISK7110のアイゾット試験法に従い、室温23℃下にてノッチなしで測定した。
(8)タック性:硬化前樹脂組成物を60-80℃で溶融させバーコーターで100g/m2の厚みで離型紙等の基材上に塗布し、40μmの厚みのポリエチレンフィルムをカバー材として密着させ、25℃で樹脂残りなく引きはがすことができるかどうかで判定した。問題なく引きはがせたものを○、引きはがし表面に樹脂残りがみられるものを×とした。
(9)破壊靭性:JIS K 6911の形状に金型注型によって成形した硬化物を試験片とし、万能試験機を用いて、室温23℃下、クロスヘッドスピード0.5mm/分の条件で試験を行った。尚、試験前における試験片へのノッチ(刻み目)の作成は、剃刀の刃を試験片にあて、ハンマーで剃刀の刃に衝撃を与えることで行った。
・エポキシ樹脂(a):日鉄ケミカル&マテリアル製エポトートYDF-170、ビスフェノールF型エポキシ樹脂、エポキシ当量=170、水酸基当量=2489
・ポリオール(b):ADEKA製アデカポリエーテルP-2000、ポリプロピレングリコール、数平均分子量2000、水酸基当量1020
・ポリカーボネートジオール化合物(b-2):旭化成製デュラノールT5652、ポリカーボネートジオール、数平均分子量2000、水酸基当量991
・ポリイソシアネート(c):三井化学製コスモネートPH、4,4’-ジフェニルメタンジイソシアネート
・低分子量ポリオール(d):1,4-ブタンジオール(試薬)
・液状エポキシ樹脂(B):日鉄ケミカル&マテリアル製エポトートYD-128、ビスフェノールA型エポキシ樹脂、エポキシ当量=187
・固形エポキシ樹脂(C):
(C-1)ビスフェノールA型2官能固体エポキシ樹脂(YD-014、日鉄ケミカル&マテリアル製、常温固体)
(C-2)ビスフェノールA型2官能固体エポキシ樹脂(YD-019、日鉄ケミカル&マテリアル製、常温固体)
・そのほかのエポキシ樹脂(E):フェノールノボラック型2官能エポキシ樹脂(KDPN-1020、日鉄ケミカル&マテリアル製、常温液体)
・硬化剤(D):EVONIK製DICYANEX 1400F、ジシアンジアミド
・硬化促進剤(F):キュアゾール2MA-OK(四国化成工業製)
エポキシ樹脂(a)として“エポトートYDF-170”、ポリオール(b)として“アデカポリエーテルP-2000”、ポリカーボネートジオール(b-2)として“デュラノールT5652”、ポリイソシアネート(c)として“コスモネートPH”、低分子量ポリオール(d)として、1,4-ブタンジオールを使用した。これらの使用量を表1に示す。
窒素導入管、攪拌機、温度調節機を備えた1000ml四つ口セパラブルフラスコに、エポトートYDF-170、アデカポリエーテルP-2000、およびデュラノールT5652を仕込み、室温で15分間攪拌混合した。次に、コスモネートPHを添加し、120℃で2h反応させた(反応1:ウレタンプレポリマー工程、この反応生成物を1次反応物という。)。
その後、1,4-ブタンジオールを加えて、120℃で2h反応させて(反応2:ポリウレタン工程)、ポリウレタン変性ビスフェノールF型エポキシ樹脂を得た(樹脂1)。ここで、エポキシ樹脂(a)は、反応2の生成物100重量%に対して72重量%となるように仕込んだ。また、OH基とNCO基のモル比(b)+(b-2):(c)は1:2.4とした。また、1次反応物中NCO基:(d)中OH基は1とした。反応が完結していることは、IR測定により、NCO基の吸収スペクトルが消失したことで確認した。
原料仕込み組成を表1~2記載の通りとした以外は、合成例1と同じ手順で反応を行い、ポリウレタン変性ビスフェノールF型エポキシ樹脂(樹脂2~10;樹脂番号は合成例番号と対応)を得た。
なお、1次反応物中NCO基:(d)中OH基(モル比)は、いずれも1とした。反応が完結していることは、IR測定により、NCO基の吸収スペクトルが消失したことで確認した。
ポリウレタン変性エポキシ樹脂(A)として、合成例1で得たポリウレタン変性ビスフェノールF型エポキシ樹脂(樹脂1)、ポリウレタン未変性液状エポキシ樹脂(B)としてエポトートYD-128、ビスフェノール型固形エポキシ樹脂(C)としてYD-014(C-1)、またはYD-019(C-2)、そのほかのエポキシ樹脂(E)としてKDPN-1020、硬化剤(D)としてジシアンジアミド、硬化促進剤(F)として2MA-OKを、各々表3記載の配合で300mlの専用ディスポカップに仕込み、自転・公転ラボ用真空プラネタリーミキサーを用いて20分間真空脱泡しつつ攪拌混合し、液状の樹脂組成物を得た。ここで、エポキシ基とジシアンジアミドのモル比は、1:0.5とし、硬化物中のポリウレタン濃度が11.1wt%となるポリウレタン変性ビスフェノールF型エポキシ樹脂組成物を140g調製した。
次に、この液状樹脂組成物をJISK7110のアイゾット衝撃試験用試験片寸法の溝形状を有する金型に注型した。曲げ試験用試験片寸法、および破壊靭性試験片寸法は100mmL×10mmW×4mmt、DMA試験用試験片寸法は100mmL×10mmW×1mmtの金型もしくはシリコン製枠に注液し、測定に適したサイズにカットして用いた。このときの注型性は、余裕をもって十分注型可能なレベルであった。次に、樹脂を注型した金型を熱風オーブン中に入れ、130℃で50分、さらに150℃で50分の加熱硬化を行い、エポキシ樹脂硬化物試験片を調製した。この試験片を使用した試験結果を、表3に示す。
ポリウレタン変性エポキシ樹脂(A)、未変性液状エポキシ樹脂(B)、未変性固形エポキシ樹脂(C-1)、(C-2)、そのほかのエポキシ樹脂(E)、硬化剤(D)および硬化促進剤(F)を表3~4記載の配合組成とした以外は、実施例1と同じ手順で硬化物中のポリウレタン濃度が変更されたポリウレタン変性ビスフェノールF型エポキシ樹脂組成物を調製した。
次に、実施例1と同様の手順で液状樹脂組成物を金型注型して熱硬化させ、特性評価用の試験片を調製した。得られた組成物の物性及び試験結果を表3~4に示す。
Claims (7)
- 下記成分(A)~(D);
(A)分子内にポリカーボネート構造を有し、ウレタン変性率が20~60重量%であるポリウレタン変性エポキシ樹脂、
(B)30℃で液状のポリウレタン未変性エポキシ樹脂、
(C)ガラス転移温度または融点が50℃以上のビスフェノール型の固形エポキシ樹脂、及び
(D)ジシアンジアミドまたはその誘導体であるアミン系硬化剤、
を必須成分とするエポキシ樹脂組成物であって、
成分(A)~(D)の合計に対し、成分(A)を20.0~50.0重量%、成分(B)を0.1~50.0重量%、成分(C)を0.1~50.0重量%含有することを特徴とするエポキシ樹脂組成物。 - 成分(A)が、重量平均分子量(Mw)が10,000以上50,000以下のポリウレタン変性エポキシ樹脂であることを特徴とする請求項1または2に記載のエポキシ樹脂組成物
- 成分(A)が、下記式(2)で示され、エポキシ当量150~200g/eqで、水酸基当量2000~3000g/eqのビスフェノール系エポキシ樹脂(a)を、数平均分子量200以上の中高分子量ポリオール化合物(b)、ポリカーボネートジオール化合物(b-2)、ポリイソシアネート化合物(c)および鎖長延長剤としての数平均分子量200未満の低分子量ポリオール化合物(d)によって変性してなり、
エポキシ樹脂(a)を、成分(a)、(b)、(b‐2)、(c)及び(d)の合計量に対して50~80重量%使用し、かつポリカーボネートジオール(b‐2)を成分(b)及び(b‐2)の合計量に対して20~55重量%となる使用量にて、エポキシ樹脂(a)と成分(b)、(b‐2)、及び(c)を反応させて、ウレタンプレポリマー(P)を生成させたのち、ウレタンプレポリマー(P)のNCO基と低分子量ポリオール化合物(d)のOH基のモル比が0.9:1~1:0.9の範囲になるように低分子量ポリオール化合物(d)を加えてポリウレタン化反応させることによって得られるエポキシ樹脂(a)が付加したポリウレタン変性エポキシ樹脂である請求項1~3のいずれか一項に記載のエポキシ樹脂組成物。
- 下記式(2)で示され、エポキシ当量150~200g/eqで、水酸基当量2000~3000g/eqのビスフェノール系エポキシ樹脂(a)を、
数平均分子量200以上の中高分子量ポリオール化合物(b)、ポリカーボネートジオール化合物(b‐2)、ポリイソシアネート化合物(c)および鎖長延長剤としての数平均分子量200未満の低分子量ポリオール化合物(d)によって変性してポリウレタン変性エポキシ樹脂とするに当たり、
エポキシ樹脂(a)を、成分(a)、(b)、(b‐2)、(c)及び(d)の合計量に対して50~80重量%使用し、かつポリカーボネートジオール(b‐2)を成分(b)及び(b‐2)の合計量に対して20~55重量%となる使用量にて、エポキシ樹脂(a)と成分(b)、(b-2)及び(c)を反応させて、ウレタンプレポリマー(P)を生成させたのち、ウレタンプレポリマー(P)のNCO基と低分子量ポリオール化合物(d)のOH基のモル比が0.9:1~1:0.9の範囲になるように低分子量ポリオール化合物(d)を加えてポリウレタン化反応させて、エポキシ樹脂(a)が付加したウレタン変性率が20~60重量%であるポリウレタン変性エポキシ樹脂を製造すること、およびこのポリウレタン変性エポキシ樹脂を上記成分(A)として使用することを特徴とする請求項1~4のいずれか一項に記載のエポキシ樹脂組成物を製造する方法。
- 請求項1~4のいずれか一項に記載のエポキシ樹脂組成物を硬化させたことを特徴とするエポキシ樹脂硬化物。
- ガラス転移温度が110℃以上、JISK7110によるアイゾット衝撃強度値(ノッチなし)が30kJ/m2以上、弾性率2.5GPa以上、破壊靭性2.0MPa・m0.5以上である請求項5に記載のエポキシ樹脂硬化物。
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JP2017226717A (ja) | 2016-06-20 | 2017-12-28 | Dic株式会社 | ポリカーボネート変性エポキシ樹脂及び接着剤 |
CN109535376A (zh) * | 2018-12-03 | 2019-03-29 | 山东天庆科技发展有限公司 | 一种高剥离强度水性环氧聚氨酯的制备方法 |
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EP1916285A1 (de) * | 2006-10-24 | 2008-04-30 | Sika Technology AG | Derivatisiertes Epoxid-Festharz und dessen Verwendungen |
CN108026424B (zh) * | 2015-09-15 | 2020-12-08 | 3M创新有限公司 | 粘合剂组合物和由其制造的制品 |
CN110054744B (zh) * | 2019-03-20 | 2021-06-04 | 浙江华峰新材料有限公司 | 改性环氧树脂增强聚氨酯组合料及其制备方法和应用 |
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JPH06206980A (ja) * | 1993-01-13 | 1994-07-26 | Toho Rayon Co Ltd | 難燃性エポキシ樹脂組成物及びプリプレグ |
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JP2016011409A (ja) | 2014-06-03 | 2016-01-21 | 学校法人 名古屋電気学園 | ポリウレタン変性エポキシ樹脂、その製造方法、エポキシ樹脂組成物および硬化物 |
JP2017082128A (ja) | 2015-10-29 | 2017-05-18 | Dic株式会社 | 繊維強化複合材料用エポキシ樹脂組成物 |
JP2017226717A (ja) | 2016-06-20 | 2017-12-28 | Dic株式会社 | ポリカーボネート変性エポキシ樹脂及び接着剤 |
WO2019188399A1 (ja) * | 2018-03-30 | 2019-10-03 | 日鉄ケミカル&マテリアル株式会社 | 低濃度ポリウレタン変性エポキシ樹脂、その製造方法、エポキシ樹脂組成物および硬化物 |
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CN109535376A (zh) * | 2018-12-03 | 2019-03-29 | 山东天庆科技发展有限公司 | 一种高剥离强度水性环氧聚氨酯的制备方法 |
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US20220306798A1 (en) | 2022-09-29 |
JPWO2021060226A1 (ja) | 2021-04-01 |
CN114502647A (zh) | 2022-05-13 |
US11702502B2 (en) | 2023-07-18 |
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