CN111417512A - 纤维增强层压体及其制造方法 - Google Patents

纤维增强层压体及其制造方法 Download PDF

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Publication number
CN111417512A
CN111417512A CN201880076702.4A CN201880076702A CN111417512A CN 111417512 A CN111417512 A CN 111417512A CN 201880076702 A CN201880076702 A CN 201880076702A CN 111417512 A CN111417512 A CN 111417512A
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China
Prior art keywords
fibers
fiber
resin composition
containing resin
short
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CN201880076702.4A
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English (en)
Inventor
瀬上幸太
渡边和伸
榎户俊文
小林祐介
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Toyo Seikan Group Holdings Ltd
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Toyo Seikan Group Holdings Ltd
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Publication of CN111417512A publication Critical patent/CN111417512A/zh
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Abstract

本发明涉及至少具有织物状纤维的层和由含短纤维树脂组合物形成的层的纤维增强层压体,及其制造方法。因为在作为构成所述织物状纤维的纤维束彼此交叉的结果而形成的间隙内存在所述含短纤维树脂组合物,所以纤维增强层压体不仅具有优异的滑动性能,并且提供耐磨耗性和强度二者。

Description

纤维增强层压体及其制造方法
技术领域
本发明涉及纤维增强层压体及其制造方法。更具体地,本发明涉及具有优异的滑动性能并且进一步具有耐磨耗性和强度二者的纤维增强层压体,及其制造方法。
背景技术
由通过将例如碳纤维等的功能性纤维共混在树脂中制备的纤维增强树脂形成的成形体的例如耐候性、机械强度、和耐久性等的特性优异,因此,成形体在例如汽车和航空器等的运输设备、土木和建筑材料、体育用品等的用途中广泛使用。
例如,以下专利文献1记载了包括特定的沥青系碳短纤维混合物和基质树脂的碳纤维增强树脂成形体。专利文献1进一步记载了成形体适合用于各种电子部件。
此外,以下专利文献2提出包括含有特定的芳香族聚酰亚胺低聚物作为碳纤维等的粘结剂的摩擦材料用树脂组合物的摩擦材料。常规地,优选使用酚醛树脂作为用于摩擦材料的粘结剂。根据专利文献2,芳香族聚酰亚胺低聚物的粘结剂与常规粘结剂相比,耐热性和机械特性优异,并且其成形性良好。
当将纤维增强树脂成形体用作例如轴承等的滑动性构件时,要求其具有各种特性。例如,要求成形体具有高的例如强度、和刚性等的机械强度。此外,要求其动摩擦系数小并且其磨耗量少,以及要求其极限PV值高等。还要求成形体含有机械强度、耐热性和耐久性优异,并且此外树脂的含浸性优异的加成反应型聚酰亚胺树脂作为基质树脂。
专利文献3涉及本发明人的发明。该文献提出通过将加成反应型聚酰亚胺树脂的预聚物和功能性纤维在加成反应型聚酰亚胺树脂的熔点以上且热固化开始温度以下的温度下混炼,并且将由此获得的混合物在加成反应型聚酰亚胺树脂的热固化开始温度以上的温度条件下成形来制备纤维增强聚酰亚胺树脂成形体。
现有技术:
专利文献:
专利文献1:JP 4538502 B2
专利文献2:JP 2009-242656 A
专利文献3:JP 2016-60914 A
发明内容
发明要解决的问题
专利文献3中记载的纤维增强聚酰亚胺树脂成形体由于其基本不产生翘曲,所以具有优异的形状稳定性。然而,该成形体具有难以实现耐磨耗性和强度二者的问题。
即,当将纤维增强聚酰亚胺树脂成形体用作滑动构件时,由于滑动面上的摩擦而刮擦的磨耗粉末会转移至配合材料(mating material)的表面以形成转移膜,从而改善耐磨耗性。然而,由于能够形成这样的转移膜的纤维增强聚酰亚胺树脂成形体为了有效地产生磨耗粉末的目的而含有比较短的碳纤维等,所以强度不令人满意,因此,成形体不能用作适用于冲击或大的负荷的滑动构件。
因此,本发明的一个目的是提供具有优异的滑动性能、并且具有耐磨耗性和强度二者的纤维增强层压体,及其制造方法。
用于解决问题的方案
本发明提供一种层压体,其至少包括织物状纤维的层和由含短纤维树脂组合物形成的层,其中在构成织物状纤维的纤维束彼此交叉形成的间隙内,存在含短纤维树脂组合物。
优选本发明的层压体中:
1.所述短纤维的长度比所述间隙的一边的长度更短;
2.所述短纤维的长度在1至350μm的范围内;
3.所述含短纤维树脂组合物包括其中分散有短纤维的加成反应型聚酰亚胺树脂;
4.所述织物状纤维和所述短纤维包括碳纤维;
5.所述由含短纤维树脂组合物形成的层和所述织物状纤维的层交替层压。
本发明还提供一种上述层压体的制造方法。在方法中,在将含短纤维树脂组合物供给至成形模具的步骤之后,将织物状纤维设置在含短纤维树脂组合物上的步骤和将含短纤维树脂组合物供给在织物状纤维上的步骤重复至少一次;然后进行压缩成形。
在本发明的层压体的制造方法中,优选的是含短纤维树脂组合物为通过将短纤维分散在加成反应型聚酰亚胺树脂中而形成的树脂组合物,并且在加成反应型聚酰亚胺树脂的热固化温度以上的温度下进行压缩成形。
发明的效果
在本发明的纤维增强层压体中,具有优异的强度的织物状纤维的层和耐磨耗性优异的由含短纤维树脂组合物形成的层交替层压。而且,由于含短纤维树脂组合物存在于通过使织物状纤维中的纤维束交叉而形成的间隙中,因此优异的耐磨耗性和强度能够长时间保持。
此外,由于基质树脂为用作含短纤维树脂组合物的加成反应型聚酰亚胺树脂,所以不仅可以改善强度而且可以改善耐热性。
因为本发明的纤维增强层压体包括存在于层压体的表面上的由含短纤维树脂组合物形成的层,可以在配合材料上形成转移膜,从而显著改善耐磨耗性。即使当织物状纤维配置在层压体表面上时,或者当使用开始后,使表面的由含短纤维树脂组合物形成的层磨耗以使织物状纤维露出时,因为织物状纤维的间隙中存在的短纤维树脂组合物露出表面,所以转移膜可以形成在配合材料上。结果,可以长期改善耐磨耗性。
进一步地,根据本发明的纤维增强层压体的制造方法,可以有效地使含短纤维树脂组合物存在于织物状纤维的间隙中,并且可以以高生产性制造具有上述优异的耐磨耗性和强度的层压体。
附图说明
[图1]为示意性示出本发明的纤维增强层压体的一个实例的透视图。
[图2]为示出图1所示的层压体在除去最上层的状态下的透视图。
[图3]为示意性示出图1所示的层压体中使用的织物状纤维的图,包括图3(A)作为平面图,和图3(B)作为图3(A)的部分放大图。
[图4]为示出滑动磨耗试验的方法的图。
具体实施方式
(层压体)
如图1中示意性示出的,本发明的层压体为通过由织物状纤维形成的层1和由含短纤维树脂组合物形成的层2交替层压而成的盘状的层压体,其中最上层2a和最下层2b包括由含短纤维树脂组合物形成的层2。
图2是示意性示出将最上层的由含短纤维树脂组合物形成的层2a除去的层压体的透视图。含短纤维树脂组合物进入通过使露出层压体表面的由织物状纤维形成的层1的纤维束3a和3b交叉形成的间隙4,以便用含短纤维树脂组合物填充间隙。因此,即使当本发明的层压体的最外表面上存在织物状纤维时,间隙4中存在的含短纤维树脂组合物可以在磨耗时部分地刮擦,并且转移至配合材料。这赋予层压体优异的耐磨耗性。
此外,如图1所示,由织物状纤维形成的层1和由含短纤维树脂组合物形成的层2的交替层压可以使层压体获得优异的强度和耐磨耗性。
图3是示出图1所示的层压体中使用的织物状纤维的示意图。图3包括示出纤维束和间隙的放大图。此处,A和B分别表示通过使构成织物状纤维的纤维束3a和3b交叉形成的各个间隙4的最大宽度和最大高度。在本发明中优选的是,含短纤维树脂组合物中含有的短纤维的纤维长度L满足L<A和/或L<B。由此,可以使短纤维通过间隙而有效地露出由织物状纤维形成的层的表面,因此,即使当将最外表面的由含短纤维树脂组合物形成的层磨耗时,也可以不损害耐磨耗性。
图中示出的具体实例是指盘形状的层压体。本发明不限于该实例,而是可以具有例如矩形等的平板状,以及此外通过将织物状纤维的层和由含短纤维树脂组合物形成的层同心圆状层压而形成的环状等任何常规已知的形状。
(织物状纤维)
本发明中使用的织物状纤维具有通过使纤维束纵横交叉形成的间隙。间隙的具体尺寸可以根据短纤维的长度而改变。图3示出的间隙的最大宽度(A)和最大高度(B)二者优选在200至1000μm的范围内,并且特别优选在250至500μm的范围内。当间隙比以上范围更小时,短纤维可能无法充分通过间隙露出表面,并且与间隙尺寸在以上范围内的情况相比,不能长期改善耐磨耗性。另一方面,当网目粗时,织物状纤维的强度降低,并且与间隙尺寸在以上范围内的情况相比,不能充分地改善层压体的强度。
纤维束的宽度优选在800至1600μm的范围内,厚度优选在100至200μm的范围内,并且织物状纤维的最大厚度优选在200至400μm的范围内。
对于构成织物状纤维的纤维,可以适合地使用常规已知的功能性纤维,并且实例包括碳纤维、芳纶纤维、玻璃纤维、和金属纤维等。它们之中,可以特别优选使用碳纤维。
碳纤维由平均纤维直径在5至18μm范围内的连续纤维形成。可以优选使用捆绑成具有1000至2000μm的宽度和100至200μm的厚度的碳纤维束。当平均纤维直径小于以上范围时,不能有效地制作纤维束并且它们经济性劣化。当平均纤维直径超过以上范围时,织物状纤维的操作性会劣化。纤维可以是PAN系纤维或沥青系纤维,只要根据目的适当地使用纤维即可,但是PAN系纤维因为优异的强度而是优选的。
(含短纤维树脂组合物)
本发明中使用的含短纤维树脂组合物自身能够形成滑动构件。上述由织物状纤维形成的层用含短纤维树脂组合物夹持,以便使得层彼此紧密贴合并且固定,同时,短纤维进入织物状纤维的间隙中。结果,即使当将最外表面的由含短纤维树脂组合物形成的层磨耗,并且织物状纤维露出时,由于织物状纤维的间隙中存在短纤维,所以也可以维持优异的耐磨耗性。
[树脂]
在本发明中,用作含有短纤维的基质的树脂可以是常规用于滑动构件等的具有耐热性和机械强度的热塑性树脂或热固性树脂。
热塑性树脂的实例包括:例如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚对苯二甲酸丙二醇酯、聚萘二甲酸乙二醇酯、液晶聚酯等的聚酯;例如聚丙烯等的聚烯烃;和间规聚苯乙烯树脂。实例进一步包括:聚甲醛、聚酰胺、聚碳酸酯、聚苯醚、聚苯硫醚、聚酰亚胺、聚酰胺酰亚胺、聚醚酰亚胺、聚砜、聚醚砜、聚酮、聚醚酮、聚醚醚酮、聚醚酮酮、聚芳酯、聚醚腈和聚四氟乙烯等。
热固性树脂的实例包括不饱和聚酯树脂、乙烯酯树脂、环氧树脂、酚醛树脂、脲-三聚氰胺树脂、和聚酰亚胺树脂等。
进一步的实例包括共聚物及其改性材料,和作为两种以上的树脂的共混物的树脂,或者含有为了改善耐冲击性而添加的弹性体或橡胶组分的树脂。
在这些树脂中,本发明特别优选使用加成反应型聚酰亚胺树脂。
本发明中使用的加成反应型聚酰亚胺树脂由在其末端具有加成反应基团的芳香族聚酰亚胺低聚物形成。其可以通过常规已知的方法来制备。例如,其可以通过使用芳香族四羧酸二酐、芳香族二胺和分子内具有酸酐基或氨基以及加成反应基团的化合物,以使各酸基的当量的合计和各氨基的合计基本相等而容易地获得。优选使酸基和氨基在溶剂中反应。在方法中,在100℃以下、优选80℃以下的温度下进行聚合0.1至50小时,以生成具有氨基酸键的低聚物,然后,用酰亚胺化剂化学地酰亚胺化。另外的实例是指包括在约140℃至约270℃范围内的高温下加热以进行热酰亚胺化的两个步骤的方法。可选的实例是指包括从开始在140至270℃范围内的高温下进行聚合-酰亚胺化反应0.1至50小时的单一步骤的方法。
可以优选地在这些反应中使用的溶剂的实例包括例如N-甲基-2-吡咯烷酮、N,N-二甲基甲酰胺、N,N-二甲基乙酰胺、N,N-二乙基乙酰胺、γ-丁基内酯、和N-甲基己内酰胺等的有机极性溶剂,但本发明不限于这些实例。
在本发明中,芳香族酰亚胺低聚物的末端的加成反应基团没有特别限制,只要其是在层压体的制造中通过加热进行固化反应(加成聚合反应)的基团即可。当考虑适合地进行固化反应的能力和获得的固化物的良好的耐热性时,其优选为选自由苯基乙炔基、乙炔基、纳迪克酸(nadic acid)基、和马来酰亚胺基组成的组的任意反应基团。苯基乙炔基是特别优选的,因为其通过固化反应不生成气态组分,并且获得的层压体的耐热性优异,并且机械强度也优异。
将这些加成反应基团通过分子内具有酸酐基或氨基以及加成反应基团的化合物(优选在芳香族酰亚胺低聚物的末端具有氨基或酸酐基)形成酰亚胺环的反应来导入芳香族酰亚胺低聚物的末端。
可以优选使用的分子内具有酸酐基或氨基以及加成反应基团的化合物的实例包括4-(2-苯基乙炔基)邻苯二甲酸酐、4-(2-苯基乙炔基)苯胺、4-乙炔基-邻苯二甲酸酐、4-乙炔基苯胺、纳迪克酸酐、和马来酸酐等。
形成在末端具有加成反应基团的芳香族酰亚胺低聚物的四羧酸组分的实例包括选自由2,3,3',4'-联苯四羧酸二酐、2,2',3,3'-联苯四羧酸二酐、3,3',4,4'-联苯四羧酸二酐、和3,3',4,4'-二苯甲酮四羧酸二酐组成的组中的至少一种四羧酸二酐。特别地,可以适合地使用2,3,3',4'-联苯四羧酸二酐。
形成在末端具有加成反应基团的芳香族酰亚胺低聚物的二胺组分的实例包括:例如1,4-二氨基苯、1,3-二氨基苯、1,2-二氨基苯、2,6-二乙基-1,3-二氨基苯、4,6-二乙基-2-甲基-1,3-二氨基苯、3,5-二乙基甲苯-2,4-二胺、和3,5-二乙基甲苯-2,6-二胺等的具有一个苯环的二胺;例如4,4'-二氨基二苯醚、3,4'-二氨基二苯醚、3,3'-二氨基二苯醚、3,3'-二氨基二苯甲酮、4,4'-二氨基二苯甲酮、4,4'-二氨基二苯基甲烷、3,3'-二氨基二苯基甲烷、双(2,6-乙基-4-氨基苯氧基)甲烷、双(2-乙基-6-甲基-4-氨基苯基)甲烷、4,4'-亚甲基-双(2,6-二乙基苯胺)、4,4'-亚甲基-双(2-乙基-6-甲基苯胺)、2,2-双(3-氨基苯基)丙烷、2,2-双(4-氨基苯基)丙烷、联苯胺、2,2-双(三氟甲基)联苯胺、3,3'-二甲基联苯胺、2,2-双(4-氨基苯基)丙烷、和2,2-双(3-氨基苯基)丙烷等的具有两个苯环的二胺;例如1,3-双(4-氨基苯氧基)苯、1,3-双(3-氨基苯氧基)苯、1,4-双(4-氨基苯氧基)苯、和1,4-双(3-氨基苯氧基)苯等的具有三个苯环的二胺;和例如2,2-双[4-[4-氨基苯氧基]苯基]丙烷、和2,2-双[4-[4-氨基苯氧基]苯基]六氟丙烷等的具有四个苯环的二胺,但本发明不限于这些实例。这些可以单独使用,或者作为多种组分的混合物使用。
优选使用包括选自由1,3-二氨基苯、1,3-双(4-氨基苯氧基)苯、3,4'-二氨基二苯醚、4,4'-二氨基二苯醚、和2,2'-双(三氟甲基)联苯胺组成的组中的至少两种芳香族二胺的混合二胺。从耐热性和成形性的观点,特别地优选使用包括1,3-二氨基苯和1,3-双(4-氨基苯氧基)苯的组合的混合二胺;包括3,4'-二氨基二苯醚和4,4'-二氨基二苯醚的组合的混合二胺;包括3,4'-二氨基二苯醚和1,3-双(4-氨基苯氧基)苯的组合的混合二胺;包括4,4'-二氨基二苯醚和1,3-双(4-氨基苯氧基)苯的组合的混合二胺;和包括2,2'-双(三氟甲基)联苯胺和1,3-双(4-氨基苯氧基)苯的组合的混合二胺。
在本发明中,使用在其末端具有加成反应基团的芳香族酰亚胺低聚物。芳香族酰亚胺低聚物优选具有0至20个、特别地1至5个重复单元,并且通过GPC以苯乙烯换算的数均分子量为10000以下,特别地3000以下。当重复单元的重复数在上述范围内时,使熔融粘度调整至适当的范围,以便可以使短纤维均匀地混合,并且含短纤维树脂组合物可以有效地嵌入织物状纤维的间隙中。除此之外,不需要在高温下成形,因此,可以提供具有优异的成形性、并且进一步具有优异的耐热性和机械强度的层压体。
重复单元的重复数可以通过改变芳香族四羧酸二酐、芳香族二胺、和分子内具有酸酐基或氨基以及加成反应基团的化合物的比例来调整。通过提高分子内具有酸酐基或氨基以及加成反应基团的化合物的比例,由于降低分子量而引起重复单元的重复数减小。当化合物的比例减小时,由于提高分子量而引起重复单元的重复数增大。
可以根据层压体的预期用途,将例如阻燃剂、着色剂、润滑剂、热稳定剂、光稳定剂、紫外线吸收剂、填料等的树脂添加剂根据已知的配方共混在加成反应型聚酰亚胺树脂中。
[短纤维]
期望的是本发明中使用的短纤维的长度(L)比织物状纤维的间隙的一边的长度(A和/或B)更小,并且特别优选的是长度在1至350μm的范围内。
对于短纤维,与上述织物状纤维同样,也可以使用例如碳纤维、芳纶纤维、玻璃纤维、金属纤维、石墨、PTFE、二硫化钼、碳纳米管、炭黑等任意常规已知的功能性纤维,并且特别地,可以适合地使用碳纤维。
它们之中,可以优选使用平均纤维长度为200μm以下并且平均纤维直径在5至18μm范围内的碳纤维,并且特别地,可以适合地使用中间相型沥青系碳纤维。当长度超过以上范围时,纤维不能有效地存在于织物状纤维的间隙中。当平均纤维直径小于以上范围时,操作性可能劣化,并且成本可能提高。当平均纤维直径超过以上范围时,功能性纤维的沉降速度可能增大并且功能性纤维倾向于不均匀分布。此外,纤维的强度倾向于降低,使得增强材料的效果可能不充分。
短纤维的含量对层压体的滑动性能和成形时的翘曲的发生有重大影响。在本发明中,优选的是,以相对于100重量份树脂为5至200重量份、特别是10至150重量份的量含有短纤维,以便获得具有优异的滑动性能和没有翘曲的优异的形状稳定性的成形体。当短纤维的含量小于以上范围时,滑动性能可能降低,并且层压体的翘曲的发生可能增大。当短纤维的含量超过以上范围时,与短纤维的含量在以上范围内的情况相比,滑动性能可能降低,并且可能发生过度的增稠从而抑制成形。
在本发明中,与短纤维一起,含短纤维树脂组合物可以进一步含有例如石墨、PTFE、二硫化钼和炭黑等的细碳系材料,和例如铝粉和铜粉等的金属粉等的无机材料的至少一种。优选以相对于100重量份树脂为5至40重量份、特别是5至30重量份的量含有上述无机材料。当无机材料的量小于以上范围时,通过将无机材料共混获得的效果可能不充分。当无机材料的量超过以上范围时,可能损害滑动性能。例如,摩擦系数可能增大,或者耐磨耗性可能降低。
(层压体的制造方法)
本发明的层压体可以用以下方式制造。具体地,将含短纤维树脂组合物供给至成形模具,随后将织物状纤维设置在制成最外表面层的含短纤维树脂组合物上,此外,将含短纤维树脂组合物供给在织物状纤维上。在使将织物状纤维设置在含短纤维树脂组合物上的步骤和将含短纤维树脂组合物供给至织物状纤维上的步骤重复至少一次或与层压数相对应的几次之后,进行压缩成形。图1示出具有四层由含短纤维树脂组合物形成的层和三层由织物状纤维形成的层,总计七层的层压体。在该情况下,将含短纤维树脂组合物供给至成形模具,然后,将织物状纤维的设置步骤和含短纤维树脂组合物的供给步骤重复三次,其后,进行压缩成形。由此,可以使含短纤维树脂组合物浸渍在织物状纤维中。同时,树脂组合物的短纤维可以容易地进入织物状纤维的间隙中。通过在层压方向进行压缩成形,可以改善由含短纤维树脂组合物形成的层和织物状纤维的层之间的层间密合性,此外,短纤维可能进一步进入织物状纤维的间隙中。结果,间隙中存在的短纤维的量会增多。
在本发明的层压体的制造方法中,首先,将用作最外表面的含短纤维树脂组合物供给至形状对应于成形体的形状的成形模具。在下文中,使用具有由包含加成反应型聚酰亚胺树脂作为基质的含短纤维树脂组合物形成的层的层压体的制造方法。
在本发明中,用作含短纤维树脂组合物的基质的加成反应型聚酰亚胺树脂在交联和固化前的预聚物的状态下具有低粘度。因此,为了使短纤维均匀分散,在将含短纤维树脂组合物供给至成形模具的步骤之前,将加成反应型聚酰亚胺树脂(酰亚胺低聚物)预聚物和短纤维在加成反应型聚酰亚胺树脂的熔点以上且热固化开始温度以下的温度下混炼,以便使预聚物的粘度增大,并且可以优选将短纤维混合以均匀分散而不沉降在预聚物中。由于短纤维均匀分散在由含短纤维树脂组合物形成的层中,所以可以形成没有翘曲的层压体。
将加成反应型聚酰亚胺树脂的预聚物(酰亚胺低聚物)和短纤维在加成反应型聚酰亚胺树脂的熔点以上的温度下加热以使预聚物熔融的同时混炼,由此将预聚物和短纤维混合以制备液状的含短纤维树脂组合物。在该情况下,优选的是,以相对于100重量份加成反应型聚酰亚胺为5至200重量份、特别是10至150重量份的量使用短纤维。上述无机材料也可以以上述的量共混。
预聚物和短纤维的混炼可以使用例如亨舍尔混合机、转鼓混合机、和螺带式混合机等的任意常规已知的混合机。它们之中,由于在抑制或减少短纤维的断裂的同时将短纤维分散是重要的,所以特别优选使用间歇式加压捏合机(混炼机)。
接着,将含短纤维树脂组合物在300至320℃的温度条件下的熔融粘度调整至10至5000Pa·s的范围内。如果熔融粘度小于10Pa·s,通过在组合物中使用的聚酰亚胺树脂的热固化开始温度附近即310±10℃的温度下使组合物保持30至60分钟来将熔融粘度调整至以上范围。
即,当通过使用电炉等将液状的含短纤维树脂组合物在310±10℃的温度下保持30至60分钟时,预聚物逐渐开始交联,由此,粘度上升。此外,粘度的上升使得共混在预聚物中的短纤维维持分散状态,而不在预聚物中沉降。通过将加热温度和保持时间设定在以上范围内,可仅将粘度上升至以上范围内,而预聚物不会完全交联固化。
在加成反应型聚酰亚胺树脂中,反应开始温度依赖于加成反应基团。期望将具有适合作为本发明的加成反应基团的苯基乙炔基的聚酰亚胺树脂在热固化开始温度附近即310±10℃的温度下加热30至60分钟。
将熔融粘度调整至以上范围的含短纤维树脂组合物供给至成形模具之后,将织物状纤维设置在其上,并且将含短纤维树脂组合物进一步供给至织物状纤维上。重复这些步骤以获得期望的层结构。在供给用作最外表面的含短纤维树脂组合物的混合物之后,在聚酰亚胺树脂的热固化开始温度以上的温度条件下进行压缩成形,由此使期望的层压体成形。通过以该方式压缩成形,通过在含短纤维树脂组合物和织物状纤维上施加压力,将含短纤维树脂组合物浸渍在织物状纤维中。特别地,用含短纤维树脂组合物填充织物状纤维的间隙,以便可以改善含短纤维树脂组合物和织物状纤维之间的层间密合性。此外,如上所述,可以长时间显示耐磨耗性。
从生产性等的观点,优选在将含短纤维树脂组合物如上所述供给至成形模具之前,调整含短纤维树脂组合物的熔融粘度。同时,甚至通过使含短纤维树脂组合物冷却凝固并且粉碎混合而制备的固形物,可以通过使用电炉等在加成反应型聚酰亚胺树脂的熔点以上的温度下加热并且熔融而同样地成形。也可以通过将固形物供给至成形模具内、在成形模具内将固形物熔融,然后设置织物状纤维以通过共同加热而固化来使层压体成形。
在使用如工程塑料等的热塑性树脂作为含短纤维树脂组合物的基质的情况下,将树脂加热至热塑性树脂的熔点以上的温度以使树脂成为熔融状态。将熔融状态的树脂供给至其上以上述方式设置有织物状纤维的成形模具,并且将熔融状态的热塑性树脂进一步供给在织物状纤维上。然后,将热塑性树脂和织物状纤维压缩成形、冷却凝固,从而使层压体成形。
实施例
[耐磨耗性]
使用根据JIS K 7218(塑料的滑动磨耗试验方法)的推力-型磨耗试验机(由A&DCorporation制造的摩擦磨耗试验机EFM-III-F),通过图4示出的环对盘(ring-on-disk)方法,在负荷(W)为300N、速度为0.5m/s、滑动距离(L)为3km(试验时间100分钟)、和配合材料为S45C(表面粗糙度Ra=0.8μm)的条件下进行滑动磨耗试验。通过使用三维轮廓形状测量器(由TOKYO SEIMITSU CO.,LTD.制造的SURFCOM2000SD3),从试验片上的槽的形状来测量磨耗量(体积V),其中根据下式(1)计算比磨耗量Ws。
Ws[mm3/N·m]=V/WL…(1)
[弯曲强度]
参考JIS K 7171(塑料-弯曲特性的试验方法),使用Autograph(由ShimadzuCorporation制造的AG-I/50N-10kN),在试验片的长度为50mm、宽度为10mm、和厚度为3至5mm的试验条件下进行弯曲试验,从而测量弯曲应力。
[夏比冲击强度]
参考JIS K 7077(碳纤维增强塑料的夏比冲击试验方法)和JIS K 7111-1(塑料-夏比冲击特性的测定),使用数字冲击试验机(由Toyo Seiki Seisaku-sho Ltd.制造的DG-UB型),在试验片尺寸为长度80mm、宽度10mm、和厚度3至6mm,打击方向为水平方向,并且标称摆能为0.5J、4J和15J的测量条件下进行夏比冲击试验。以这样的方式测量夏比冲击强度。
(实施例1)
在100重量份加成聚合型聚酰亚胺(由Ube Industries,Ltd.制造的PETI-330)中共混43重量份的平均纤维长度为200μm的沥青系碳纤维(由Mitsubishi ChemicalCorporation制造的K223HM),并且使混合物在电炉中在大气压下在280℃下熔融30分钟。随后,将混合物冷却至室温,由此获得含短纤维树脂组合物。将由此获得的含短纤维树脂组合物粉碎至容易处理的尺寸,并且供给至成型模具。其后,将织物状纤维(200-目的碳布)的设置和含短纤维树脂组合物的供给的一系列步骤重复三次。将成型模具加热至280℃并且保持10分钟。随后,在3℃/min的升温速度下升温至320℃并且保持30分钟以调整粘度。然后,在加压至3MPa的同时,在4.3℃/min的升温速度下进一步升温至371℃,并且保持60分钟。通过退火,获得直径为200mm和厚度为4mm的板。将由此获得的板材加工为期望的尺寸以获得试验片。
(实施例2)
除了将用于含短纤维树脂组合物的碳纤维更改为通过将实施例1中使用的并且平均纤维长度为200μm的沥青系碳纤维粉碎而获得的平均纤维长度为10μm的沥青系碳纤维以外,通过与实施例1相同的方式提供试验片。
(比较例1)
在100重量份加成聚合型聚酰亚胺(由Ube Industries,Ltd.制造的PETI-330)中共混43重量份的平均纤维长度为200μm的沥青系碳纤维(由Mitsubishi ChemicalCorporation制造的K223HM),并且使混合物在电炉中在大气压下在280℃下熔融30分钟。随后,使混合物冷却至室温,由此获得含短纤维树脂组合物。将由此获得的含短纤维树脂组合物粉碎至容易处理的尺寸,并且供给至加热至280℃的成型模具并且保持10分钟。随后,升温至320℃并且保持30分钟以调整粘度。然后,在加压至3MPa的同时,在4.3℃/min的升温速度下进一步升温至371℃,并且保持60分钟。通过退火,获得直径为200mm和厚度为3mm的板。将由此获得的板材加工为期望的尺寸以获得试验片。
(比较例2)
除了将用于含短纤维树脂组合物的碳纤维更改为通过将比较例1中使用的并且平均纤维长度为200μm的沥青系碳纤维粉碎而获得的平均纤维长度为10μm的沥青系碳纤维以外,通过与比较例1相同的方式提供试验片。
(比较例3)
将十二张织物状碳纤维(200-目碳布)供给至在280℃加热的成型模具内,以便使总厚度为3mm。然后,供给相对于100重量份织物状碳纤维为100重量份的加成聚合型聚酰亚胺(由Ube Industries,Ltd.制造的PETI-330),并且保持10分钟以熔融。随后,在3℃/min的升温速度下升温至320℃并且保持30分钟以调整粘度。然后,在加压至3MPa的同时,在4.3℃/min的升温速度下进一步升温至371℃,并且保持60分钟。通过退火,获得直径为200mm和厚度为3mm的板。将由此获得的板材加工为期望的尺寸以获得试验片。
在实施例1至2和比较例1至3中获得的成形体的比磨耗量、弯曲强度、和夏比冲击强度显示在表1中。
[表1]
Figure BDA0002510991740000161
产业上的可利用性
本发明的树脂成形体的机械强度和耐磨耗性优异,因此,其可以在例如汽车、电气或电子领域等的滑动构件的各种用途中使用。

Claims (8)

1.一种层压体,其至少具有织物状纤维的层和由含短纤维树脂组合物形成的层,在构成所述织物状纤维的纤维束彼此交叉形成的间隙内存在所述含短纤维树脂组合物。
2.根据权利要求1所述的层压体,其中所述短纤维的长度比所述间隙的一边的长度更短。
3.根据权利要求1或2所述的层压体,其中所述短纤维的长度在1至350μm的范围内。
4.根据权利要求1至3任一项所述的层压体,其中所述含短纤维树脂组合物包括其中分散有短纤维的加成反应型聚酰亚胺树脂。
5.根据权利要求1至4任一项所述的层压体,其中所述织物状纤维和所述短纤维由碳纤维形成。
6.根据权利要求1至5任一项所述的层压体,其中所述由含短纤维树脂组合物形成的层和所述织物状纤维的层交替层压。
7.一种根据权利要求1至6任一项所述的层压体的制造方法,其包括:
将含短纤维树脂组合物供给至成形模具的步骤;
将织物状纤维设置在所述含短纤维树脂组合物上的步骤和所述含短纤维树脂组合物供给在所述织物状纤维上的步骤重复至少一次;和
进行压缩成形。
8.根据权利要求7所述的制造方法,其中所述含短纤维树脂组合物包括其中分散有短纤维的加成反应型聚酰亚胺树脂,并且在所述加成反应型聚酰亚胺树脂的热固化温度以上的温度下进行压缩成形。
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