JP2007191633A - Resin composition for prepreg sheet and prepreg sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin composition for a prepreg sheet, having excellent impregnation properties and toughness; to provide a prepreg sheet good in fillet formability, obtained by impregnating the composition into a fiber; and to provide a fiber-reinforced composite material, enabling it to have good strength by curing the prepreg sheet. <P>SOLUTION: The resin composition for the prepreg sheet contains a thermosetting resin, thermoplastic resin, curing agent, filler to adjust viscosity and toughening filler. Where the minimum viscosity during a curing process becomes 10-150 Pa s and viscosity at 100°C becomes ≤300 Pa s. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a resin composition for a prepreg sheet and a prepreg sheet. More specifically, the present invention relates to a self-adhesive prepreg sheet that does not require an adhesive sheet for bonding to a honeycomb core, and a resin composition for a prepreg sheet that can form the prepreg sheet.

Epoxy resin compositions are used in fields such as architecture, civil engineering, automobiles, and aircraft as resins having excellent heat resistance.
Fiber reinforced composite materials that use such an epoxy resin composition as a matrix resin have excellent mechanical properties, heat resistance, and water resistance. So far, prepreg sheets using combinations of epoxy resins and reinforcing fibers having various compositions have been proposed. Has been.
Also, in fiber reinforced composite materials such as aircraft structural materials, it is often formed into a structure in which the plane of a prepreg sheet is joined to the cross section of a honeycomb core having a honeycomb structure from the viewpoint of reducing the weight of the structural material. In order to bond the honeycomb core and the prepreg sheet, a sheet-like adhesive interposed between the honeycomb core and the prepreg is used.

  Therefore, from the viewpoint of shortening the manufacturing process and further weight reduction, the prepreg sheets are laminated on both sides of the honeycomb core without using a sheet-like adhesive, and the prepreg sheet itself is cured and bonded to the honeycomb core at the same time. In addition, so-called self-adhesive cocure molding performed without an adhesive has been required for prepreg sheets, and various resin compositions for prepreg sheets have been proposed (see, for example, Patent Documents 1 to 3). .

In Patent Document 1, “Epoxy resin, aromatic amine curing agent, acid anhydride curing agent, dicyandiamide curing” is used for the purpose of avoiding the generation of porosity (voids and voids generated during resin curing). Complex viscosity measured at 80 ° C. with a vibration frequency of 0.02 Hz, which is an epoxy resin composition comprising one or more curing agents selected from the group consisting of an agent and a novolak curing agent, and a solid rubber and the rate eta _0.02 is 5000 poises or more, the relationship between the complex viscosity eta _0.02 measured in complex viscosity eta ₂ and the vibration frequency 0.02Hz measured at a vibration frequency of 2Hz to logη _0.02 -logη ₂ ≧ 0.5 An "epoxy resin composition characterized by satisfaction" has been proposed.

In Patent Document 2, for the purpose of improving tackiness and draping properties, “consisting of a reinforcing fiber and a matrix resin, the matrix resin being a thermosetting resin, and a dynamic viscoelasticity at a measurement frequency of 0.5 Hz and 50 ° C. A prepreg in which the complex viscosity η ^* of the matrix resin in the measurement is in the range of 200 to 2000 Pa · s and the energy loss tan δ is in the range of 0.3 to 5 has been proposed.

On the other hand, in Patent Document 3, from the viewpoint of producing a resin film suitable for producing a prepreg in which the resin content of the prepreg is uniform and uniform, “the resin has a width of 50 cm or more on the release sheet and an average basis weight of 20 g / m ^2. In the following, there has been proposed a “resin film for prepreg production” which is applied with a basis weight variation of 10% or less as defined in the text and has a volatile content of 4% by weight or less.

  However, when a conventionally known self-adhesive prepreg sheet is used, the impregnation property of the resin composition for a prepreg sheet into fibers (hereinafter also simply referred to as “impregnation”), after the resin composition for a prepreg sheet is cured. Toughness (hereinafter also simply referred to as “toughness”) and fillet-forming properties (hereinafter also simply referred to as “fillet-forming”) during the production of fiber-reinforced composite materials (for example, honeycomb core sandwich panels). Since it is difficult to satisfy, there is a problem that the strength of the produced fiber-reinforced composite material (for example, peel strength when performing a climbing drum peel test according to ATSM D1781) is inferior.

JP-A-5-239317 JP-A-9-194611 JP-A-11-254435

  Accordingly, the present invention provides a resin composition for a prepreg sheet having excellent impregnation and toughness, a prepreg sheet having a good fillet form obtained by impregnating fibers with the resin composition for prepreg sheet, and curing the prepreg sheet. It is an object of the present invention to provide a fiber-reinforced composite material having good strength obtained by the above-described process.

As a result of intensive studies on the above problems, the present inventor has a viscosity of about 50 to 100 ° C., in particular, a low viscosity at 100 ° C. to some extent from the viewpoint of impregnation, and is usually around 120 to 150 ° C. from the viewpoint of fillet formation. It has been found that the observed minimum viscosity during curing needs to be somewhat high.
Based on this new knowledge, the viscosity-adjusting filler and toughening filler are used in combination, and the resin composition having a predetermined viscosity range at a specific temperature is excellent in impregnation and toughness, and the resin composition for prepreg sheet is used as a fiber. The prepreg sheet obtained by impregnation was found to have excellent fillet-forming properties, and the fiber-reinforced composite material obtained by curing the prepreg sheet was found to have excellent strength, and the present invention was completed.

That is, the present invention provides the following (1) to (16).
(1) It contains a thermosetting resin, a thermoplastic resin, a curing agent, a viscosity adjusting filler, and a toughening filler. The minimum viscosity during curing is 10 to 150 Pa · s, and the viscosity at 100 ° C. Is a resin composition for a prepreg sheet, which is 300 Pa · s or less.
(2) The resin composition for a prepreg sheet according to (1), wherein the thermosetting resin is an epoxy resin and / or a cyanate ester resin.
(3) The resin composition for a prepreg sheet according to the above (1) or (2), wherein the thermoplastic resin is at least one selected from the group consisting of polyethersulfone, polyetherimide, and polysulfone.
(4) The resin composition for a prepreg sheet according to any one of (1) to (3), wherein the content of the thermoplastic resin is 30 to 50 parts by mass with respect to 100 parts by mass of the thermosetting resin. .
(5) The resin composition for a prepreg sheet according to any one of (1) to (4), wherein the curing agent contains diaminodiphenyl sulfone and / or dicyandiamide.
(6) The resin composition for a prepreg sheet according to any one of (1) to (5), wherein the content of the curing agent is 25 to 45 parts by mass with respect to 100 parts by mass of the thermosetting resin.
(7) The resin composition for a prepreg sheet according to any one of (1) to (6), wherein the viscosity adjusting filler is an amorphous, acicular or spherical particle.
(8) The resin composition for a prepreg sheet according to (7), wherein the viscosity adjusting filler is fumed silica.
(9) The resin composition for a prepreg sheet according to (8), wherein the viscosity adjusting filler is fumed silica that has been subjected to surface hydrophobization treatment.
(10) The prepreg sheet according to any one of (1) to (9), wherein the content of the viscosity adjusting filler is 0.5 to 10 parts by mass with respect to 100 parts by mass of the thermosetting resin. Resin composition.
(11) The resin composition for a prepreg sheet according to any one of (1) to (10), wherein the toughening filler is a plate-like particle.
(12) The resin composition for a prepreg sheet according to (11), wherein the toughening filler is mica.
(13) Resin for prepreg sheets in any one of said (1)-(12) whose content of the said toughening filler is 0.5-10 mass parts with respect to 100 mass parts of said thermosetting resins. Composition.
(14) A prepreg sheet that can be obtained by impregnating a fiber with the resin composition for a prepreg sheet according to any one of (1) to (13).
(15) The prepreg sheet according to (14), wherein the fiber is at least one selected from the group consisting of carbon fiber, aramid fiber, and glass fiber.
(16) A fiber-reinforced composite material obtainable by curing the prepreg sheet as described in (14) or (15) above.

  According to the present invention, a resin composition for a prepreg sheet having excellent impregnation and toughness, a prepreg sheet having good fillet formability obtained by impregnating fibers with the resin composition for prepreg sheet, and curing the prepreg sheet Thus, it is possible to provide a fiber-reinforced composite material having good strength.

The present invention is described in detail below.
The resin composition for a prepreg sheet of the present invention (hereinafter also simply referred to as “the composition of the present invention”) includes a thermosetting resin, a thermoplastic resin, a curing agent, a viscosity adjusting filler, and a toughening filler. And the minimum viscosity during curing is 10 to 150 Pa · s, and the viscosity at 100 ° C. is 300 Pa · s or less.
Next, the thermosetting resin, the thermoplastic resin, the curing agent, the viscosity adjusting filler and the toughening filler used in the composition of the present invention will be described in detail.

<Thermosetting resin>
The thermosetting resin used in the composition of the present invention is not particularly limited as long as it is a synthetic resin that forms a network structure and cures in an insoluble and infusible state when heated. Specific examples thereof include urea resins and melamine resins. , Phenol resin, epoxy resin, unsaturated polyester resin, alkyd resin, urethane resin, and the like. These may be used alone or in combination of two or more.
Of these, epoxy resins, cyanate ester resins, or mixed resins that have excellent mechanical, thermal, and electrical properties, but brittleness often hinders their application expansion. This is preferable because the toughness of the resulting composition of the present invention and, in turn, the strength of the fiber-reinforced composite material of the present invention is further improved.

The epoxy resin is not particularly limited as long as it is a resin composed of a compound having two or more oxirane rings (epoxy groups) in one molecule, and generally has an epoxy equivalent of 90 to 2,000.
A conventionally well-known epoxy resin can be used as such an epoxy resin.
Specifically, for example, epoxy compounds having a bisphenyl group such as bisphenol A type, bisphenol F type, brominated bisphenol A type, hydrogenated bisphenol A type, bisphenol S type, bisphenol AF type, biphenyl type, and polyalkylene Bifunctional glycidyl ether type epoxy resins such as glycol type, alkylene glycol type epoxy compounds, epoxy compounds having a naphthalene ring, and epoxy compounds having a fluorene group;
Polyfunctional glycidyl ether type epoxy resins such as phenol novolac type, orthocresol novolak type, trishydroxyphenylmethane type, tetraphenylolethane type;
Glycidyl ester epoxy resins of synthetic fatty acids such as dimer acid;
N, N, N ′, N′-tetraglycidyldiaminodiphenylmethane (TGDDM), tetraglycidyldiaminodiphenylsulfone (TGDDS), tetraglycidyl-m-xylylenediamine (TGMXDA) represented by the following formula (1), (2) represented by triglycidyl-p-aminophenol, triglycidyl-m-aminophenol, N, N-diglycidylaniline, tetraglycidyl 1,3-bisaminomethylcyclohexane (TG1,3-BAC), tri Glycidylamine epoxy resin such as glycidyl isocyanurate (TGIC);

Formula (3) epoxy compound having a tricyclo [5,2,1,0 ^2,6] decane ring represented by, specifically, for example, cresol or phenols, such as dicyclopentadiene and cresol An epoxy compound which can be obtained by a known production method of reacting epichlorohydrin after polymerization;

（式中、ｍは、０〜１５の整数を示す。）

(In the formula, m represents an integer of 0 to 15.)

Cycloaliphatic epoxy resin; epoxy resin represented by Toray Rethiokol's Flep 10 epoxy resin having a sulfur atom in the main chain; urethane modified epoxy resin having urethane bond; polybutadiene, liquid polyacrylonitrile-butadiene rubber or acrylonitrile butadiene rubber Examples thereof include a rubber-modified epoxy resin containing (NBR).
These may be used alone or in combination of two or more.

In the present invention, the glycidylamine epoxy resin and the bisphenol F type epoxy resin are used in combination, the viscosity of the resulting composition of the present invention, the mechanical properties after curing (for example, elastic modulus, toughness, etc.) and thermal properties. It is preferable because properties (for example, glass transition temperature, coefficient of thermal expansion, etc.) can be easily adjusted, and as a result, the strength of the fiber-reinforced composite material of the present invention can be easily adjusted.
Among the glycidylamine epoxy resins, examples of the tetraglycidyldiaminodiphenylmethane (TGDDM) represented by the above formula (1) include, for example, ELM-434 (manufactured by Sumitomo Chemical Co., Ltd.), MY-721 (manufactured by Huntsman Advanced Materials). As the triglycidyl-p-aminophenol represented by the above formula (2), for example, MY-0510 (manufactured by Huntsman Advanced Material), Epicoat 630 (manufactured by Japan Epoxy Resin Co., Ltd.) can be used. ) Etc. can be used.
As the bisphenol F type epoxy resin, for example, commercially available products such as Epicoat 806 and Epicoat 807 (both manufactured by Japan Epoxy Resin Co., Ltd.) can be used.

In the present invention, when another epoxy resin is used in combination with the glycidylamine epoxy resin and the bisphenol F type epoxy resin, an epoxy resin having an aromatic ring in the skeleton is used as the other epoxy resin. It is preferable because it is convenient for optimizing the mechanical properties and thermal properties of the cured product by controlling the form.
Examples of other epoxy resins include bisphenol A type epoxy resin (Epicoat 828, manufactured by Japan Epoxy Resin Co., Ltd.), phenol novolac type epoxy resin (Epicoat 154, manufactured by Japan Epoxy Resin Co., Ltd.), and cresol novolac type epoxy resin (TETRAD-X). Commercial products such as Mitsubishi Gas Chemical Co., Ltd.).

  The cyanate ester resin is not particularly limited as long as it is represented by the following formula (4).

（式中、Ｒは芳香環を有する２価以上の有機基を表し、ｎは２以上の整数を表す。）

(In the formula, R represents a divalent or higher valent organic group having an aromatic ring, and n represents an integer of 2 or higher.)

  Specific examples of such cyanate ester resins include 1,3-dicyanate benzene, 1,4-dicyanate benzene, 1,3,5-tricyanate benzene, 1,8- or 2 , 6- or 2,7-dicyanatonaphthalene, 4,4'-dicyanatobiphenyl, bis (4-cyanatophenyl) methane, 2,2-bis (4-cyanatophenyl) propane, bis (3 , 5-dimethyl-4-cyanatophenyl) methane, 2,2-bis (3,5-dimethyl-4-cyanatophenyl) propane, bis (4-cyanatophenyl) sulfone, tris (4-cyanatophenyl) ) Phosphite, 1,1′-bis (4-cyanatophenyl) ethane, 1,3-bis (4-cyanatophenyl-1- (1-methylethylidene)) benzene, 2,2-bis (4- Shi Anatophenyl) hexafluoropropane and the like.

  In the present invention, among the various cyanate ester resins exemplified above, 1,1′-bis (4-cyanatophenyl) ethane, 1,3-bis (4-cyanatophenyl-1- (1-methylethylidene) )) It is preferable to use benzene in combination because it is easy to adjust the viscosity of the composition of the present invention and the mechanical and thermal properties after curing.

<Thermoplastic resin>
The thermoplastic resin used in the composition of the present invention is not particularly limited as long as it is a synthetic resin that can be molded by heating, and specific examples thereof include polyacetal, polyethylene (PE), polyethylene naphthalate. Phthalate, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride (PVC), polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl formal, polysulfone, polyethersulfone (PES), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyphenylene oxide , Polyarylate, polyarylene oxide, polystyrene (PS), polyamide (PA), polyimide (PI), polyetherimide (PEI), polyamideimide (PAI), polycar Sulfonates, polybenzimidazole, include polymethyl methacrylate, and the like, may be used those either alone, or in combination of two or more.
Among these, at least one selected from the group consisting of polyethersulfone, polyetherimide, and polysulfone is preferable because of its high compatibility with the thermosetting resin.

  By containing the thermoplastic resin, the fillet-forming property of the prepreg sheet of the present invention using the obtained composition of the present invention is improved, and the toughness of the composition, and thus the prepreg sheet is used. The strength of the fiber-reinforced composite material of the present invention is improved. This is considered to be because the viscosity of the resulting composition of the present invention is raised over the entire temperature range, and the network of the tough thermoplastic resin reinforces the brittle thermosetting resin.

  In the present invention, the number average molecular weight of the thermoplastic resin is preferably 10,000 to 30,000, and more preferably 15,000 to 25,000. When the number average molecular weight of the thermoplastic resin is within this range, the viscosity range of the obtained composition of the present invention becomes appropriate, and the strength of the fiber-reinforced composite material of the present invention is further improved.

  Moreover, in this invention, it is preferable that it is 30-50 mass parts with respect to 100 mass parts of said thermosetting resins, and, as for content of the said thermoplastic resin, it is more preferable that it is 35-45 mass parts. When the content of the thermoplastic resin is within this range, the impregnation property of the obtained composition of the present invention becomes better.

<Curing agent>
Curing agents used in the composition of the present invention include diaminodiphenyl sulfone (DDS), dicyandiamide (DICY), diaminodiphenylmethane (DDM), diaminodiphenyl ether (DADPE), bisaniline, benzyldimethylaniline and the like represented by the following formula (5). These may be used alone or in combination of two or more.
Among these, an aromatic amine compound having at least one aromatic hydrocarbon group and at least two amino groups in one molecule is excellent in the heat resistance of the resulting composition of the present invention. For this reason, diaminodiphenyl sulfone, dicyandiamide or a mixture thereof is preferable because the fillet-forming property of the prepreg sheet of the present invention using the resulting composition of the present invention becomes better and the toughness of the composition Further, it is more preferable because the strength of the fiber-reinforced composite material of the present invention using the prepreg sheet becomes better.

In this invention, it is preferable that it is 25-45 mass parts with respect to 100 mass parts of said thermosetting resins, and, as for content of the said hardening | curing agent, it is more preferable that it is 30-35 mass parts. When the content of the curing agent is within this range, the resulting composition of the present invention has good heat resistance, and the toughness of the composition, and thus the strength of the fiber-reinforced composite material of the present invention is better. Become.
In addition, the content of the curing agent is an equivalent ratio represented by (active hydrogen group of the curing agent) / (functional group in the thermosetting resin that reacts with the active hydrogen group in the curing agent). It is preferably 0.5 to 0.9, and more preferably 0.6 to 0.8.

<Viscosity adjusting filler>
The viscosity adjusting filler used in the composition of the present invention is not particularly limited as long as it is a filler that is dispersed in the thermosetting resin and has a viscosity increasing effect, and is an amorphous, acicular or spherical particle. Is preferred.
Specific examples of such a viscosity adjusting filler include fumed silica, calcined silica, precipitated silica, ground silica, fused silica; diatomaceous earth; iron oxide, zinc oxide, titanium oxide, barium oxide, magnesium oxide. Calcium carbonate, magnesium carbonate, zinc carbonate; wax stone clay, kaolin clay, calcined clay; carbon black; barium sulfate, basic magnesium sulfate; aluminum borate; potassium titanate; aluminum hydroxide, magnesium hydroxide; alumina; And the like. Lastite; sepiolite; attapulgite; zonolite;

  By including the viscosity adjusting filler, the viscosity of the composition of the present invention obtained is not affected at 50 to 100 ° C., particularly at 100 ° C., and is usually the lowest during curing observed at around 120 to 150 ° C. It can be seen that the viscosity is increased, and the fillet formability is good without adversely affecting the impregnation property. Among the viscosity adjusting fillers exemplified above, fumed silica is preferable for the reason that this effect is more exhibited, and fumed silica that has been subjected to surface hydrophobization treatment is the reason for further exhibiting this effect. Is more preferable.

In the present invention, the specific surface area (hereinafter referred to as “BET specific surface area”) of the above viscosity adjusting filler measured by the BET method is preferably 90 m ² / g or more, more preferably 130 m ² / g or more. Is more preferable. When the BET specific surface area of the viscosity adjusting filler is within this range, the fillet-forming property of the prepreg sheet of the present invention using the obtained composition of the present invention can be obtained even when the amount of the viscosity adjusting filler added is small. Better.

  Moreover, in this invention, it is preferable that it is 0.5-10 mass parts with respect to 100 mass parts of said thermosetting resins, and it is 1-5 mass parts with respect to 100 mass parts of said thermosetting resins. More preferred. When the content of the viscosity adjusting filler is within this range, weight reduction can be achieved without increasing the specific gravity of the resulting composition of the present invention.

<Toughening filler>
The toughening filler used in the composition of the present invention is not particularly limited as long as it is a filler that is dispersed in the thermosetting resin and has a toughening effect, and is preferably a plate-like particle.
Specific examples of such toughening fillers include mica, plate-like silica other than the viscosity adjusting filler, talc, glass flakes, and synthetic hydrotalcite.

  By including the toughening filler, the toughness of the composition, without affecting the viscosity of the resulting composition of the present invention, that is, without adversely affecting the impregnation property and fillet-forming property, The strength of the fiber-reinforced composite material of the present invention will be good. Among the toughening fillers exemplified above, mica is the most prominent in improving the toughness, and over the entire temperature range (about 25 to 200 ° C.), the viscosity of the composition of the present invention. It is preferable because it has a small influence.

In the present invention, the particle diameter of the toughening filler is preferably 45 μm or less, more preferably 30 μm or less.
Moreover, when the said toughening filler is a particle | grains which have a flat shape, as for the particle diameter, it is preferable that the average major axis is 5-45 micrometers, and it is more preferable that it is 20-30 micrometers. When the particle diameter of the toughening filler is within this range, the thickness of the prepreg sheet of the present invention using the resulting composition of the present invention can be sufficiently reduced.

  Moreover, in this invention, it is preferable that it is 0.5-10 mass parts with respect to 100 mass parts of said thermosetting resins, and, as for content of the said toughening filler, it is 1-5 mass parts more. preferable. When the content of the toughening filler is within this range, the viscosity range of the composition of the present invention obtained is appropriate, and the toughness of the composition, and consequently the strength of the fiber-reinforced composite material of the present invention, is further improved.

The composition of the present invention contains the above-described thermosetting resin, thermoplastic resin, curing agent, viscosity adjusting filler and toughening filler, and has a minimum viscosity of 10 to 150 Pa · s during curing, The viscosity at 100 ° C. is 300 Pa · s or less. As described above, the fillet formability of the prepreg sheet of the present invention using the composition of the present invention is improved by this viscosity range, particularly the lowest viscosity during curing of 10 to 150 Pa · s, at 100 ° C. When the viscosity of the composition is 300 Pa · s or less, the impregnation property of the composition of the present invention is improved.
Here, while the minimum viscosity during curing and the viscosity at 100 ° C. are increased from 25 ° C. to 200 ° C. at a rate of temperature increase of 2 ° C./min, respectively, a viscoelasticity measuring device (DMA) (for example, TA instrument) RDS-II manufactured by the same company) and the complex viscosity at 100 ° C. and the lowest value of the viscosities measured every 30 seconds at a vibration frequency of 10 rad / s.

The composition of the present invention preferably has a fracture toughness value (K _IC ) after curing of 2.00 or more. When the fracture toughness value (K _IC ) is within this range, it can be said that the toughness of the composition of the present invention is sufficiently good, and the strength of the fiber-reinforced composite material of the present invention, in particular, the peeling strength is better. Become.
Here, the fracture toughness value (K _IC ) after curing is measured by a three-point bending test with one side notch using a resin plate made of a cured product of the resin composition for prepreg, according to the method described in ASTM D5045-96. Fracture toughness value (Mpa · m ^1/2 ).
Furthermore, the fiber reinforced composite material of the present invention preferably has a peel strength of 25 (lb-in / 3 in) or more. When the peel strength is within this range, it can be suitably used as an industrial product requiring extremely high strength, particularly as an aircraft material.
Here, the peel strength refers to the peel strength (lb-in / 3 in) when a climbing drum peel test according to ATSM D1781 is performed.

  The resin composition for a prepreg sheet of the present invention is an anti-aging agent, an antioxidant, a pigment (dye), a plasticizer, a thixotropic agent, and an ultraviolet absorber as long as the purpose of the present invention is not impaired. Various additives such as an agent, a flame retardant, a solvent, a surfactant (including a leveling agent), a dispersant, a dehydrating agent, an adhesion-imparting agent, and an antistatic agent can be contained.

Specific examples of the anti-aging agent include hindered phenol compounds.
Specific examples of the antioxidant include butylhydroxytoluene (BHT) and butylhydroxyanisole (BHA).

  Specific examples of the plasticizer include dioctyl phthalate (DOP) and dibutyl phthalate (DBP); dioctyl adipate, isodecyl succinate; diethylene glycol dibenzoate, pentaerythritol ester; butyl oleate, methyl acetylricinoleate; phosphorus Examples include tricresyl acid, trioctyl phosphate; propylene glycol adipate polyester, butylene glycol adipate polyester.

Specific examples of the thixotropic agent include Aerosil (manufactured by Nippon Aerosil Co., Ltd.) and Dispalon (manufactured by Enomoto Kasei Co., Ltd.).
Specific examples of the adhesion imparting agent include terpene resins, phenol resins, terpene-phenol resins, rosin resins, and xylene resins.

Specific examples of the flame retardant include chloroalkyl phosphate, dimethylmethylphosphonate, bromine atom and / or phosphorus atom-containing compound, ammonium polyphosphate, neopentyl bromide-polyether, and brominated polyether.
Examples of the antistatic agent include quaternary ammonium salts; hydrophilic compounds such as polyglycols and ethylene oxide derivatives.

  The resin composition for a prepreg sheet of the present invention is not particularly limited with respect to its production. For example, the above-mentioned essential components and optional components may be put in a reaction vessel, and sufficiently kneaded using a stirrer such as a mixing mixer while controlling the temperature under reduced pressure.

  The resin composition for a prepreg sheet of the present invention is a one-component resin composition for a prepreg sheet containing a main component containing a thermosetting resin, a thermoplastic resin, a viscosity adjusting filler and a toughening filler, and a curing agent. Can be used as

Next, the prepreg sheet of the present invention will be described.
The prepreg sheet of the present invention is a prepreg sheet that can be obtained by impregnating fibers with the above-described resin composition for a prepreg sheet of the present invention.

Specific examples of the fiber impregnated with the resin composition for a prepreg sheet of the present invention include, for example, carbon fiber, graphite fiber, aramid fiber, silicon carbide fiber, alumina fiber, boron fiber, high-strength polyethylene fiber, and tungsten carbide fiber. , Reinforcing fibers such as PBO fiber, glass fiber, metal fiber, and the like. These may be used alone or in combination of two or more.
Among these, at least one selected from the group consisting of carbon fiber, aramid fiber, and glass fiber is preferable because the impregnation step is simple.

In the present invention, the carbon fiber is not particularly limited, and specific examples thereof include polyacrylonitrile-based carbon fiber (PAN-based carbon fiber), pitch-based carbon fiber, and the like.
Further, the carbon fiber is not particularly limited in its form and arrangement, for example, a unidirectional material in which reinforcing fibers are aligned in one direction, a woven fabric, a non-woven fabric composed of short cut reinforcing fibers, a braid, a tow, a knit, A mat etc. are mentioned. The form and arrangement | sequence of carbon fiber can be freely selected according to the site | part to be used and a use.

  In the present invention, the content of the resin composition for a prepreg sheet impregnated in such fibers is preferably 70 to 35% by volume in the entire volume of the prepreg sheet from the viewpoint of properties such as strength. 60 to 40% by volume is preferable.

The method for producing the prepreg sheet of the present invention is not particularly limited as long as the fiber is impregnated with the resin composition for a prepreg sheet of the present invention.
Examples of the impregnation method include a wet method and a hot melt method.
The impregnation is preferably performed under heating.

  When a prepreg sheet is produced by a wet method, it is preferable to dissolve the resin composition for a prepreg sheet of the present invention in a solvent to prepare a varnish and then impregnate the fiber. Examples of the solvent used when preparing the varnish include ketone solvents such as methyl ethyl ketone (MEK). The amount of the solvent used is preferably 1 to 20 parts by mass with respect to 100 parts by mass of the resin composition for a prepreg sheet of the present invention because the drying process can be shortened.

  When producing a prepreg sheet by the hot melt method, after the resin composition for a prepreg sheet of the present invention is heated and melted, it is uniformly coated on a release paper while uncured to produce a resin film, It is preferable to sandwich the fiber from both sides with a resin film, and then impregnate the resin while applying pressure and heat.

  The heating temperature during the impregnation is preferably 60 to 150 ° C. When heating temperature is 60 degreeC or more, the resin composition for prepreg sheets can fully impregnate carbon fiber, and a prepreg sheet has an appropriate tack | tuck and is excellent in handleability. When the heating temperature is 150 ° C. or lower, the resin curing reaction does not proceed excessively while the carbon fiber is impregnated with the resin composition for prepreg sheet, and the prepreg sheet is excellent in drape.

  Since the prepreg sheet of the present invention uses the composition of the present invention, no sheet-like adhesive is required for bonding to the honeycomb core, and the fillet formability is excellent.

Next, the fiber reinforced composite material of the present invention will be described.
The fiber-reinforced composite material of the present invention is a fiber-reinforced composite material that can be obtained by curing the above-described prepreg sheet of the present invention.

FIG. 1 and FIG. 2 show an example of a fiber-reinforced composite material in which a prepreg sheet and a honeycomb core are bonded, and a method for bonding the prepreg and the honeycomb core will be described. FIG. 1 is a perspective view of a fiber-reinforced composite material 1. FIG. 2 is a cross-sectional view of the fiber reinforced composite material 1 cut in parallel with the side surfaces of the prisms of the honeycomb core 11. The part a in FIG. 2 is a fiber-reinforced composite material to which a prepreg sheet formed from a conventional resin composition for a prepreg sheet is bonded, and the part b is bonded to a prepreg sheet formed from a resin composition for a prepreg of the present invention. 1 shows a fiber reinforced composite material.
As shown in FIG. 1, the fiber reinforced composite material 1 is obtained by bonding a prepreg sheet 10 and a honeycomb core 11, and the present invention is applied to one or both end faces of the end 12 of the honeycomb core showing a honeycomb structure. The prepreg sheet 10 formed of the above composition is joined, and is heated and cured by an autoclave or the like while being pressed from both ends.

However, even when the prepreg sheet 10 and the honeycomb core 11 are evenly pressed during the heat curing, the resin composition for the prepreg sheet is entirely on the bottom surface as shown in FIG. There is a case where a fillet is not formed on the upper surface portion 13 by falling on the portion 13 ′, or a gap is partially formed on the bonding surface between the prepreg sheet 10 and the honeycomb core 11.
In contrast, as shown in part b of FIG. 2, the resin composition for a prepreg sheet of the present invention is excellent in fillet-forming properties, and thus the prepreg sheet 10 and the honeycomb core 11 are completely bonded. Moreover, an appropriate amount of the resin composition for a prepreg sheet can be present in the prepreg sheet without causing the resin composition for the prepreg sheet to flow out too much from the prepreg sheet and causing the resin component to disappear from the prepreg sheet. Accordingly, curing can be completed while maintaining an appropriate shape of the upper fillet 14. Also, on the lower surface, when the viscosity is once reduced, the lower fillet 14 'is formed by the surface tension, the resin composition for the prepreg sheet is appropriately held, and the curing can be completed.

  The use of the fiber reinforced composite material of the present invention is not particularly limited, but specific examples thereof include motorcycle parts such as motorcycle frames, cowls, and fenders; doors, bonnets, tailgates, side fenders, side panels, fenders, energy absorbing members. Automobile parts such as trunk lid, hard top, side mirror cover, spoiler, diffuser, ski carrier, engine cylinder cover, engine hood, chassis, air spoiler, propeller shaft; top vehicle nose, roof, side panel, door, bogie cover, Side panels for vehicles such as side skirts; railcar parts such as luggage racks and seats; interiors, wing inner panels, outer panels, roofs, floors, etc. Which aero parts; aircraft parts such as window frames, luggage racks, seats, floor panels, wings, propellers, fuselage, etc .; casing use for notebook computers, mobile phones, etc .; medical uses such as X-ray cassettes, top boards; flat speaker panels Applications of acoustic products such as speaker cones; sports equipment applications such as golf heads, faceplates, snowboards, surfboards, protectors; and general industrial applications such as leaf springs, windmill blades, elevators (籠 panels, doors).

  Hereinafter, the present invention will be specifically described with reference to examples. However, the present invention is not limited to these.

<Thermosetting resin 1>
As the thermosetting resin 1, triglycidyl-p-aminophenol (MY-0510, manufactured by Huntsman Advanced Materials) represented by the above formula (2) was used.

<Thermosetting resin 2>
As thermosetting resin 2, bisphenol F type epoxy resin (Epicoat 806, manufactured by Japan Epoxy Resin Co., Ltd.) was used.

<Thermoplastic resin 1>
As the thermoplastic resin 1, polyethersulfone (PES) manufactured by Sumitomo Chemical Co., Ltd. was used.

<Curing agent 1>
As the curing agent 1, 3,3′-diaminodiphenylsulfone (3,3′-DDS) manufactured by Wakayama Seika Kogyo Co., Ltd. was used.

<Curing agent 2>
As the curing agent 2, dicyandiamide (Epicure DICY15, manufactured by Japan Epoxy Resin Co., Ltd.) was used.

<Viscosity adjusting filler 1>
As the viscosity adjusting filler 1, fumed silica (Aerosil 130, BET specific surface area 130 m ² / g, manufactured by Nippon Aerosil Co., Ltd.) was used.

<Viscosity adjusting filler 2>
As the viscosity adjusting filler 2, fumed silica (Aerosil 972, BET specific surface area 110 m ² / g, manufactured by Nippon Aerosil Co., Ltd.) subjected to surface hydrophobization treatment was used.

<Toughening filler 1>
As the toughening filler 1, mica (A-11, particle size 5 μm, manufactured by Yamaguchi Mica Industry) was used.

<Toughening filler 2>
As the toughening filler 2, mica (A-21, particle size 25 μm, manufactured by Yamaguchi Mica Industry) was used.

<Toughening filler 3>
As the toughening filler 3, mica (A-41, particle size 45 μm, manufactured by Yamaguchi Mica Industry Co., Ltd.) was used.

1. Preparation of resin composition for prepreg sheet (Examples 1 to 9, Comparative Examples 1 to 4)
Each of the above components was mixed using a stirrer with the composition (parts by mass) shown in Table 1 below to obtain resin compositions for prepreg sheets of Examples 1 to 9 and Comparative Examples 1 to 4.
The obtained each prepreg sheet resin composition, minimum viscosity during cure, viscosity and fracture toughness at 100 ° C. The (K _IC) were measured by the following methods. The results are shown in Table 1.

(1) Minimum viscosity during curing (abbreviated as “minimum viscosity” in Table 1 below)
While increasing the viscosity of each obtained resin composition for prepreg from 25 ° C. to 200 ° C. at a rate of temperature increase of 2 ° C./min, a viscoelasticity measuring device (DMA) (such as RDS-II manufactured by TA Instruments) Was used to determine the minimum value.
Those having a minimum viscosity of 10 Pa · s or more were evaluated as having excellent fillet-forming properties of the prepreg sheet using the prepreg resin composition.

(2) Viscosity at 100 ° C. (abbreviated as “100 ° C. viscosity” in the following Table 1)
The viscosity at 100 ° C. of each obtained prepreg resin composition was measured using a viscoelasticity measuring device (DMA).
Those having a 100 ° C. viscosity of 300 Pa · s or less were evaluated as being excellent in the impregnation property of the resin composition for prepreg into fibers.

(3) Fracture toughness value (K _IC )
Each obtained prepreg resin composition was put into a program oven, heated from 25 ° C. to 180 ° C. at a temperature rising rate of 2 ° C./min under normal pressure, and then cured at 180 ° C. for 2 hours to obtain a thickness of 7 mm. In accordance with the method described in ASTM D5045-96, the fracture toughness value (Mpa · m ^1/2 ) was measured by a one-side notched three-point bending test using this resin plate.
A prepreg sheet using a prepreg resin composition having a minimum viscosity of 10 Pa · s or more, a viscosity at 100 ° C. of 300 Pa · s or less, and a fracture toughness value of 2.00 Mpa · m ^1/2 or more. It was evaluated that the strength of the cured fiber reinforced composite material was excellent.

2. Preparation of Prepreg Sheet Each prepreg sheet resin composition was applied onto release paper using a reverse roll coater to prepare a resin film. Next, these two resin films were superposed so as to sandwich both surfaces of carbon fibers (Treka (registered trademark) T-700, tensile elastic modulus 230 GPa, manufactured by Toray Industries, Inc.) arranged in one direction in a sheet shape. Thereafter, the resin was impregnated with carbon fiber by heating and pressing to prepare a unidirectional prepreg sheet having a carbon fiber basis weight of 196 ± 5 g / cm ² and a matrix resin mass fraction of 34%. In Comparative Example 4, the mass fraction of the matrix resin did not reach 34%, and poor resin impregnation was confirmed even by observation with an optical microscope.
The impregnation property of each prepreg sheet resin composition into fibers was good except for the prepreg resin composition prepared in Comparative Example 4. Also from this result, it was confirmed that the resin composition for prepreg having a 100 ° C. viscosity of 300 Pa · s or less has excellent impregnation into fibers.

3. Preparation of Honeycomb Core Sandwich Panel Each prepreg sheet obtained was joined to both cross sections of Nomex honeycomb cores manufactured by Showa Aircraft Co., Ltd., which had a honeycomb pattern, pre-assembled by the vacuum back method, and then heated at an autoclave rate of 2 The honeycomb core sandwich panel was manufactured by raising the temperature to 180 ° C. at a forming pressure of 3 kg / cm ² and then curing at 180 ° C. for 2 hours. In addition, since the resin composition for prepreg sheets prepared in Comparative Example 4 had insufficient impregnation properties, a honeycomb core sandwich panel was not produced.
The obtained honeycomb core sandwich panel was cut in parallel with the prisms of the honeycomb core, and the fillets formed on both ends of the honeycomb core were visually confirmed. The resin for the prepreg sheet prepared in Comparative Example 3 and Examples 1 to 9 When the prepreg sheet produced using the composition was used, a fillet of 400 μm or more was formed in all cases, and the fillet forming property was good. Also from this result, it was confirmed that a resin composition for prepreg having a minimum viscosity of 10 Pa · s or more has excellent fillet-forming properties of the prepreg sheet.

Further, the obtained honeycomb core sandwich panel was subjected to a climbing drum peel test according to ATSM D1781, and the peel strength (lb-in / 3 in) was obtained. The results are shown in Table 1 above. In Comparative Example 4, since a honeycomb core sandwich panel was not manufactured, “−” was shown in Table 1 above.
As a result, the honeycomb core sandwich panel using the prepreg sheet prepared using the prepreg sheet resin composition prepared in Examples 1 to 9 has an exfoliation strength of 25 (lb-in / 3 in) or more, and extremely high strength. Has been found to be suitable for industrial products, particularly aircraft applications. Also from this result, it was confirmed that the strength of the fiber-reinforced composite material of the present invention was excellent.

As is clear from the results shown above, the resin compositions for prepreg sheets prepared in the examples have a viscosity at 100 ° C. and a minimum viscosity in a predetermined range, and a fracture toughness value (K _IC ) is also good. It can be seen that the impregnation and toughness are good. Further, from the results of producing the prepreg sheet and the honeycomb core sandwich panel, it was confirmed that the fillet-forming property of the prepreg sheet and the strength of the honeycomb core sandwich panel were good.

FIG. 1 is a perspective view of a fiber-reinforced composite material including a honeycomb core and a prepreg sheet. FIG. 2 is a cross-sectional view of a fiber-reinforced composite material including a honeycomb core and a prepreg sheet.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Fiber reinforced composite material 10 Prepreg sheet | seat 11 Honeycomb core 12 End part 13 Upper surface part 13 'Lower surface part 14 Upper fillet 14' Lower fillet a Structure using the prepreg formed with the conventional matrix resin b The composition of this invention is matrix Structure using resin prepreg c Cell size

Claims (16)

Containing a thermosetting resin, a thermoplastic resin, a curing agent, a viscosity adjusting filler, and a toughening filler;
A resin composition for a prepreg sheet, having a minimum viscosity during curing of 10 to 150 Pa · s and a viscosity at 100 ° C. of 300 Pa · s or less.   The resin composition for a prepreg sheet according to claim 1, wherein the thermosetting resin is an epoxy resin and / or a cyanate ester resin.   The resin composition for a prepreg sheet according to claim 1 or 2, wherein the thermoplastic resin is at least one selected from the group consisting of polyethersulfone, polyetherimide, and polysulfone.   The resin composition for a prepreg sheet according to any one of claims 1 to 3, wherein a content of the thermoplastic resin is 30 to 50 parts by mass with respect to 100 parts by mass of the thermosetting resin.   The resin composition for a prepreg sheet according to any one of claims 1 to 4, wherein the curing agent contains diaminodiphenyl sulfone and / or dicyandiamide.   Content of the said hardening | curing agent is 25-45 mass parts with respect to 100 mass parts of said thermosetting resins, The resin composition for prepreg sheets in any one of Claims 1-5.   The resin composition for a prepreg sheet according to any one of claims 1 to 6, wherein the viscosity adjusting filler is an amorphous, acicular or spherical particle.   The resin composition for a prepreg sheet according to claim 7, wherein the viscosity adjusting filler is fumed silica.   The resin composition for a prepreg sheet according to claim 8, wherein the viscosity adjusting filler is fumed silica that has been subjected to a surface hydrophobization treatment.   The resin composition for a prepreg sheet according to any one of claims 1 to 9, wherein a content of the viscosity adjusting filler is 0.5 to 10 parts by mass with respect to 100 parts by mass of the thermosetting resin.   The resin composition for a prepreg sheet according to any one of claims 1 to 10, wherein the toughening filler is a plate-like particle.   The resin composition for a prepreg sheet according to claim 11, wherein the toughening filler is mica.   The resin composition for a prepreg sheet according to any one of claims 1 to 12, wherein a content of the toughening filler is 0.5 to 10 parts by mass with respect to 100 parts by mass of the thermosetting resin.   A prepreg sheet that can be obtained by impregnating a fiber with the resin composition for a prepreg sheet according to claim 1.   The prepreg sheet according to claim 14, wherein the fiber is at least one selected from the group consisting of carbon fiber, aramid fiber, and glass fiber.   A fiber-reinforced composite material obtainable by curing the prepreg sheet according to claim 14 or 15.

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