JP2020094100A - VaRTM成形用樹脂組成物、成形材料、成形品及び成形品の製造方法 - Google Patents
VaRTM成形用樹脂組成物、成形材料、成形品及び成形品の製造方法 Download PDFInfo
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- JP2020094100A JP2020094100A JP2018231625A JP2018231625A JP2020094100A JP 2020094100 A JP2020094100 A JP 2020094100A JP 2018231625 A JP2018231625 A JP 2018231625A JP 2018231625 A JP2018231625 A JP 2018231625A JP 2020094100 A JP2020094100 A JP 2020094100A
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Landscapes
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Abstract
Description
また、上記、オープンモールド成形に対して、生産性や成形品の強度を高める目的で、予め型面を離型処理した金属やFRP製のキャビ(凹)型およびコア(凸)型内の空隙部に繊維強化材を賦形、配置し、型内の空隙部に常温または加熱により硬化可能なラジカル硬化性樹脂組成物を注入、繊維強化材を含浸し、必要により型加熱により硬化させた後、脱型して成形品を得るレジントランスファーモールディング(RTM)成形や、コア型(上型)の代わりにフィルムを用いて、キャビ(凹)型とフィルムの間に繊維強化材を賦形、配置し、型内を減圧することによりラジカル硬化性樹脂を型内に引き込み、繊維強化材を含浸し、必要により型加熱により硬化させた後、脱型して成形品を得るバキュームインフュージョン成形等のクローズドモールド成形が行われている。
さらに生産性を追求したFRPの成形方法として、予め繊維強化材に樹脂および充填材、硬化収縮抑制材、硬化剤を含む樹脂組成物を含浸させたコンパウンドをシート状に増粘させたシートモールディングコンパウンド(SMC)や、コパウンドを塊状としたバルクモールディングコンパウンド(BMC)を、金型を用いて高温、高圧でプレスして硬化後、脱型して成形品を得る圧縮(プレス)成形が行われている。
先述、オープンモールド成形は、製品寸法の制約を受けず、低設備投資で行える成形方法として優れるが、成形の大部分の工程を人手で行うため生産性の向上が難しい。また、生産性に優れる圧縮(プレス)成形については、金型やプレス等大型の付帯設備への多大な初期設備投資を要し、金型製作には高額を要すため製品のモデルチェンジサイクルの短い製品や少量多品種生産には不向きの他、対応できる製品寸法にも型、附帯設備面からの制約を受ける。
そこで、プレス成形に比べ低設備投資で、オープンモールド成形よりも生産性の向上が図れる成形方法として、バキュームアシストレジントランスファーモールディング(VaRTM)の導入、移行が進みつつある。さらにVaRTM成形は、繊維強化材の選択や、長繊維の繊維強化材を用いることができ、繊維の含有量や、その配向を最適化することにより製品の形状や用途に応じた強度や弾性率の要求に合わせ、より薄肉、軽量で製品設計することができるなどの利点を有することから、導入、量産化技術開発が近年盛んに行われている(例えば、特許文献1。)。
温度計、窒素導入管、撹拌機を設けた2Lフラスコに、エポキシ樹脂(DIC株式会社製「エピクロン850」、ビスフェノールA型エポキシ樹脂、エポキシ当量188)754質量部、ビスフェノールA 181質量部、を仕込み、撹拌しながら110℃に昇温した。ここに2−メチルイミダゾール0.40質量部を入れ、反応物のエポキシ当量が380になるまで110℃で反応を行った。次いでメタクリル酸202質量部、及びハイドロキノン0.40質量部を仕込み、窒素と空気とを1対1で混合したガス流通下で、90℃まで昇温した。ここに2−メチルイミダゾール1.00質量部を入れ、105℃に昇温して反応を継続させ、酸価が9以下で反応を終了した。60℃付近まで冷却した後、反応容器より取り出し、エポキシメタクリレート(A−1)を得た。
温度計、窒素導入管、撹拌機を設けた2Lフラスコに、エポキシ樹脂(DIC株式会社製「エピクロン850」、ビスフェノールA型エポキシ樹脂、エポキシ当量188)856質量部、ビスフェノールA 140質量部、を仕込み、撹拌しながら110℃に昇温した。ここに2−メチルイミダゾール0.40質量部を入れ、反応物のエポキシ当量が310になるまで110℃で反応を行った。次いでメタクリル酸272質量部、及びハイドロキノン0.40質量部を仕込み、窒素と空気とを1対1で混合したガス流通下で、90℃まで昇温した。ここに2−メチルイミダゾール1.00質量部を入れ、105℃に昇温して反応を継続させ、酸価が10以下で反応を終了した。60℃付近まで冷却した後、反応容器より取り出し、エポキシメタクリレート(A−2)を得た。
温度計、窒素導入管、撹拌機を設けた2Lフラスコに、エポキシ樹脂(DIC株式会社製「エピクロン850」、ビスフェノールA型エポキシ樹脂、エポキシ当量188)805質量部、ビスフェノールA 207質量部、を仕込み、撹拌しながら110℃に昇温した。ここに2−メチルイミダゾール0.40質量部を入れ、反応物のエポキシ当量が420になるまで110℃で反応を行った。次いでメタクリル酸197質量部、及びハイドロキノン0.40質量部を仕込み、窒素と空気とを1対1で混合したガス流通下で、90℃まで昇温した。ここに2−メチルイミダゾール1.00質量部を入れ、105℃に昇温して反応を継続させ、酸価が7以下で反応を終了した。60℃付近まで冷却した後、反応容器より取り出し、エポキシメタクリレート(A−3)を得た。
合成例1で得たエポキシメタクリレート(A−1)48質量部をスチレン52質量部に溶解させた樹脂溶液100質量部に、ハイドロキノン0.008質量部を添加しVaRTM成形用樹脂組成物(1)を得た。このVaRTM成形用樹脂組成物(1)の粘度は、25℃において80mPa・sであった。
上記VaRTM成形用樹脂組成物(1)100質量部に対して、硬化促進剤として6%オクチル酸コバルト(DICマテリアル株式会社製「促進剤RP−330」)0.2質量部、重合開始剤(化薬アクゾ株式会社製「トリゴノックス40」、アセチルアセトンパーオキサイド)1.0質量部を均一に配合し、真空脱泡を行った後、内側表面を離型処理した2枚のガラス板で上縁部以外を3mm厚のシリコンゴム製パッキンで封じて形成した空隙を型として注型、常温で24時間、硬化させた後、120℃の乾燥機内で2時間アフターキュアを実施し、成形品X(1)を得た。
上記で得られた成形品X(1)について、JIS K7191−1に準拠し、荷重たわみ温度を測定し、耐熱性を評価した。荷重たわみ温度の値が大きいほど、耐熱性が良好である。
上記で得られた成形品X(1)について、JIS K7161−1及び2に準拠し、1B試験片の引張試験を行い、引張強さ及び伸びを測定した。
型面(400mm×400mm)に、ガラス繊維強化材(株式会社日東紡製、「WF350 100 BS6R 」、平織クロス、330g/m2)250mm×250mm:7プライ、樹脂供給ライン、減圧ラインとしてφ6mmスパイラルチューブを配置し、その上にピールプライ(AIRTECH社製「BleederLeaseB」)、フローメディア(AIRTECH社製「Greenflow75」)、バギングフィルム(AIRTECH社製「KM1300」)で順に覆い、バギングフィルム周縁と型面および、樹脂供給、減圧ホースの間をシールテープ(AIRTECH社製「AT−200Y」)で密閉した。樹脂供給ホースは、樹脂槽底面に届く長さとした。また、減圧ホースは、減圧ゲージを介して、真空ポンプに接続した。
樹脂槽手前の樹脂供給ホースをバイスプライヤーで遮断し、真空ポンプを運転させ、型とバギングフィルムの間の気密を確認、減圧ゲージで10kPa以下を保持した。
上記、減圧度を保持したまま、樹脂槽に、VaRTM成形用樹脂組成物(1)を300質量部、硬化促進剤として6%オクチル酸コバルト(DICマテリアル株式会社製「促進剤RP−330」)0.6質量部、重合開始剤(化薬アクゾ株式会社製「トリゴノックス40」、アセチルアセトンパーオキサイド)3.0質量部を均一に配合し、真空脱泡を行った後、移し入れた。
樹脂供給ホースのバイスプライヤーを解放し、型とフィルム間のガラス繊維強化材への樹脂の注入を開始した。約5分でガラス繊維強化材全面への注入を終え、樹脂供給ホース、減圧ホースをバイスプライヤーで遮断した。そのまま、常温でゲル化させた後、60℃で1時間、後硬化させ成形品Y(1)を得た。得られた成形品Y(1)の板厚は2.0mmで、ガラス繊維含有率は49.6体積%であった。
上記で得られた成形品Y(1)の外観を目視により下記の基準に従い評価した。
○:未含浸部なし
×:未含浸あり
合成例2で得たエポキシメタクリレート(A−2)50質量部をスチレン50質量部に溶解させた樹脂溶液100質量部に、ハイドロキノン0.008質量部を添加しVaRTM成形用樹脂組成物(2)を得た。このVaRTM成形用樹脂組成物(2)の粘度は、25℃において60mPa・sであった。
合成例2で得たエポキシメタクリレート(A−2)65質量部をスチレン35質量部に溶解させた樹脂溶液100質量部に、ハイドロキノン0.008質量部を添加しVaRTM成形用樹脂組成物(R1)を得た。このVARTM成形用樹脂組成物(R1)の粘度は、25℃において500mPa・sであった。
合成例3で得たエポキシメタクリレート(A−3)40質量部をスチレン60質量部に溶解させた樹脂溶液100質量部に、ハイドロキノン0.008質量部を添加しVaRTM成形用樹脂組成物(R2)を得た。このVaRTM成形用樹脂組成物(R2)の粘度は、25℃において40mPa・sであった。
Claims (4)
- エポキシ(メタ)アクリレート(A)及びスチレン(B)を含有するVaRTM成形用樹脂組成物であって、前記エポキシ(メタ)アクリレート(A)の原料であるエポキシ樹脂のエポキシ当量が250〜500の範囲であり、前記エポキシ(メタ)アクリレート(A)と前記スチレン(B)との質量比(A/B)が60/40〜45/55の範囲であることを特徴とするVaRTM成形用樹脂組成物。
- 25℃における粘度が50〜300mPa・sの範囲である請求項1記載のVaRTM成形用樹脂組成物。
- 請求項1又は2記載のVaRTM成形用樹脂組成物、重合開始剤(C)、及び繊維強化材(D)を含有することを特徴とする成形材料。
- 請求項3記載の成形材料の硬化物であることを特徴とする成形品。
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