JP2020521860A - フェノール系成型材料 - Google Patents
フェノール系成型材料 Download PDFInfo
- Publication number
- JP2020521860A JP2020521860A JP2019566209A JP2019566209A JP2020521860A JP 2020521860 A JP2020521860 A JP 2020521860A JP 2019566209 A JP2019566209 A JP 2019566209A JP 2019566209 A JP2019566209 A JP 2019566209A JP 2020521860 A JP2020521860 A JP 2020521860A
- Authority
- JP
- Japan
- Prior art keywords
- uncured
- phenolic resin
- fibers
- substrate
- resin sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 title abstract description 22
- 239000012778 molding material Substances 0.000 title abstract description 3
- 239000000463 material Substances 0.000 claims abstract description 166
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 156
- 239000005011 phenolic resin Substances 0.000 claims abstract description 152
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 139
- 239000002131 composite material Substances 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims description 54
- 239000000758 substrate Substances 0.000 claims description 53
- 239000000835 fiber Substances 0.000 claims description 47
- 239000000945 filler Substances 0.000 claims description 38
- 229920005989 resin Polymers 0.000 claims description 35
- 239000011347 resin Substances 0.000 claims description 35
- 239000003054 catalyst Substances 0.000 claims description 30
- 238000003825 pressing Methods 0.000 claims description 19
- 239000006260 foam Substances 0.000 claims description 13
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 13
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 11
- 150000004692 metal hydroxides Chemical class 0.000 claims description 11
- 238000000465 moulding Methods 0.000 claims description 11
- 239000003365 glass fiber Substances 0.000 claims description 10
- 229910052723 transition metal Inorganic materials 0.000 claims description 9
- 150000003624 transition metals Chemical group 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical group O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 239000000049 pigment Substances 0.000 claims description 7
- 239000007787 solid Substances 0.000 claims description 7
- 239000004034 viscosity adjusting agent Substances 0.000 claims description 7
- WEVYAHXRMPXWCK-UHFFFAOYSA-N Acetonitrile Chemical compound CC#N WEVYAHXRMPXWCK-UHFFFAOYSA-N 0.000 claims description 6
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 6
- 235000013312 flour Nutrition 0.000 claims description 6
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 claims description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 229920003023 plastic Polymers 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 5
- 239000000843 powder Chemical group 0.000 claims description 5
- HEDRZPFGACZZDS-UHFFFAOYSA-N Chloroform Chemical compound ClC(Cl)Cl HEDRZPFGACZZDS-UHFFFAOYSA-N 0.000 claims description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical group CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 229910044991 metal oxide Inorganic materials 0.000 claims description 4
- 150000004706 metal oxides Chemical class 0.000 claims description 4
- 239000004576 sand Substances 0.000 claims description 4
- 229910000288 alkali metal carbonate Inorganic materials 0.000 claims description 3
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 150000004649 carbonic acid derivatives Chemical class 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 229910010272 inorganic material Inorganic materials 0.000 claims description 3
- 239000011147 inorganic material Substances 0.000 claims description 3
- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- 239000002699 waste material Substances 0.000 claims description 3
- 239000002023 wood Substances 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 2
- 229920002472 Starch Polymers 0.000 claims description 2
- 239000004760 aramid Substances 0.000 claims description 2
- 229920006231 aramid fiber Polymers 0.000 claims description 2
- 239000010425 asbestos Substances 0.000 claims description 2
- 239000004917 carbon fiber Substances 0.000 claims description 2
- 235000013339 cereals Nutrition 0.000 claims description 2
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 239000011651 chromium Substances 0.000 claims description 2
- 239000002734 clay mineral Substances 0.000 claims description 2
- 239000002817 coal dust Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 229910017052 cobalt Inorganic materials 0.000 claims description 2
- 239000010941 cobalt Substances 0.000 claims description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 2
- 239000004744 fabric Substances 0.000 claims description 2
- 229910052742 iron Inorganic materials 0.000 claims description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 2
- 239000004005 microsphere Substances 0.000 claims description 2
- 239000002557 mineral fiber Substances 0.000 claims description 2
- 229920005749 polyurethane resin Polymers 0.000 claims description 2
- 239000011819 refractory material Substances 0.000 claims description 2
- 229910052895 riebeckite Inorganic materials 0.000 claims description 2
- 239000011435 rock Substances 0.000 claims description 2
- 229910052706 scandium Inorganic materials 0.000 claims description 2
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 239000008107 starch Substances 0.000 claims description 2
- 235000019698 starch Nutrition 0.000 claims description 2
- 229920002994 synthetic fiber Polymers 0.000 claims description 2
- 239000012209 synthetic fiber Substances 0.000 claims description 2
- 229910052720 vanadium Inorganic materials 0.000 claims description 2
- 239000010455 vermiculite Substances 0.000 claims description 2
- 229910052902 vermiculite Inorganic materials 0.000 claims description 2
- 235000019354 vermiculite Nutrition 0.000 claims description 2
- 239000004927 clay Substances 0.000 claims 1
- 239000010881 fly ash Substances 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 claims 1
- 230000001939 inductive effect Effects 0.000 claims 1
- 238000007493 shaping process Methods 0.000 claims 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims 1
- 239000000203 mixture Substances 0.000 abstract description 14
- 230000003197 catalytic effect Effects 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 16
- 238000002845 discoloration Methods 0.000 description 10
- 230000000694 effects Effects 0.000 description 9
- 230000008569 process Effects 0.000 description 9
- 150000001875 compounds Chemical class 0.000 description 8
- 238000001723 curing Methods 0.000 description 8
- LEQAOMBKQFMDFZ-UHFFFAOYSA-N glyoxal Chemical compound O=CC=O LEQAOMBKQFMDFZ-UHFFFAOYSA-N 0.000 description 8
- -1 alkali metal salt Chemical class 0.000 description 7
- 230000008901 benefit Effects 0.000 description 7
- 239000003381 stabilizer Substances 0.000 description 7
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 6
- 239000003086 colorant Substances 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 241001061127 Thione Species 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 5
- POFWRMVFWIJXHP-UHFFFAOYSA-N n-benzyl-9-(oxan-2-yl)purin-6-amine Chemical compound C=1C=CC=CC=1CNC(C=1N=C2)=NC=NC=1N2C1CCCCO1 POFWRMVFWIJXHP-UHFFFAOYSA-N 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- ABLZXFCXXLZCGV-UHFFFAOYSA-N Phosphorous acid Chemical class OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 4
- 239000002253 acid Substances 0.000 description 4
- 230000002378 acidificating effect Effects 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 229940015043 glyoxal Drugs 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 238000009827 uniform distribution Methods 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- WMFOQBRAJBCJND-UHFFFAOYSA-M Lithium hydroxide Chemical compound [Li+].[OH-] WMFOQBRAJBCJND-UHFFFAOYSA-M 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229910052783 alkali metal Inorganic materials 0.000 description 3
- 239000002585 base Substances 0.000 description 3
- 239000011449 brick Substances 0.000 description 3
- 231100001010 corrosive Toxicity 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 230000003278 mimic effect Effects 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical compound OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 2
- QUSNBJAOOMFDIB-UHFFFAOYSA-N Ethylamine Chemical compound CCN QUSNBJAOOMFDIB-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000003377 acid catalyst Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000000280 densification Methods 0.000 description 2
- JXTHNDFMNIQAHM-UHFFFAOYSA-N dichloroacetic acid Chemical compound OC(=O)C(Cl)Cl JXTHNDFMNIQAHM-UHFFFAOYSA-N 0.000 description 2
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 2
- 230000008570 general process Effects 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 235000006408 oxalic acid Nutrition 0.000 description 2
- 150000002989 phenols Chemical class 0.000 description 2
- 239000004848 polyfunctional curative Substances 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- CPRMKOQKXYSDML-UHFFFAOYSA-M rubidium hydroxide Chemical compound [OH-].[Rb+] CPRMKOQKXYSDML-UHFFFAOYSA-M 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- UMGDCJDMYOKAJW-UHFFFAOYSA-N thiourea Chemical compound NC(N)=S UMGDCJDMYOKAJW-UHFFFAOYSA-N 0.000 description 2
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- OGYGFUAIIOPWQD-UHFFFAOYSA-N 1,3-thiazolidine Chemical compound C1CSCN1 OGYGFUAIIOPWQD-UHFFFAOYSA-N 0.000 description 1
- MFGOFGRYDNHJTA-UHFFFAOYSA-N 2-amino-1-(2-fluorophenyl)ethanol Chemical compound NCC(O)C1=CC=CC=C1F MFGOFGRYDNHJTA-UHFFFAOYSA-N 0.000 description 1
- RVBUGGBMJDPOST-UHFFFAOYSA-N 2-thiobarbituric acid Chemical compound O=C1CC(=O)NC(=S)N1 RVBUGGBMJDPOST-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- YPXQSGWOGQPLQO-UHFFFAOYSA-N 5-nitro-1,3-dihydrobenzimidazole-2-thione Chemical compound [O-][N+](=O)C1=CC=C2N=C(S)NC2=C1 YPXQSGWOGQPLQO-UHFFFAOYSA-N 0.000 description 1
- 241000264877 Hippospongia communis Species 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FCSHMCFRCYZTRQ-UHFFFAOYSA-N N,N'-diphenylthiourea Chemical compound C=1C=CC=CC=1NC(=S)NC1=CC=CC=C1 FCSHMCFRCYZTRQ-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920010741 Ultra High Molecular Weight Polyethylene (UHMWPE) Polymers 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Natural products NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- 238000003916 acid precipitation Methods 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- RQPZNWPYLFFXCP-UHFFFAOYSA-L barium dihydroxide Chemical compound [OH-].[OH-].[Ba+2] RQPZNWPYLFFXCP-UHFFFAOYSA-L 0.000 description 1
- 229910001863 barium hydroxide Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- HUCVOHYBFXVBRW-UHFFFAOYSA-M caesium hydroxide Inorganic materials [OH-].[Cs+] HUCVOHYBFXVBRW-UHFFFAOYSA-M 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 159000000007 calcium salts Chemical class 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- FOCAUTSVDIKZOP-UHFFFAOYSA-N chloroacetic acid Chemical compound OC(=O)CCl FOCAUTSVDIKZOP-UHFFFAOYSA-N 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 229960005215 dichloroacetic acid Drugs 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 238000009730 filament winding Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 239000005338 frosted glass Substances 0.000 description 1
- BRWIZMBXBAOCCF-UHFFFAOYSA-N hydrazinecarbothioamide Chemical compound NNC(N)=S BRWIZMBXBAOCCF-UHFFFAOYSA-N 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910017053 inorganic salt Inorganic materials 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 238000013035 low temperature curing Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- ACVYVLVWPXVTIT-UHFFFAOYSA-N phosphinic acid Chemical class O[PH2]=O ACVYVLVWPXVTIT-UHFFFAOYSA-N 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229920003987 resole Polymers 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000010454 slate Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 239000011232 storage material Substances 0.000 description 1
- 229920001576 syndiotactic polymer Polymers 0.000 description 1
- 235000012222 talc Nutrition 0.000 description 1
- 150000007970 thio esters Chemical class 0.000 description 1
- 125000005323 thioketone group Chemical group 0.000 description 1
- 150000003585 thioureas Chemical class 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000012780 transparent material Substances 0.000 description 1
- YNJBWRMUSHSURL-UHFFFAOYSA-N trichloroacetic acid Chemical compound OC(=O)C(Cl)(Cl)Cl YNJBWRMUSHSURL-UHFFFAOYSA-N 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
- C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
- C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
- C08G8/10—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with phenol
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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Abstract
Description
−未硬化フェノール系樹脂と、
−フィラーと、
−フェノール系樹脂の含有量に対して2wt.%未満の量の触媒と
を含み、フィラーが、2.5:1以上の量のフィラー対未硬化フェノール系樹脂の比で存在し、さらにフィラーが、遷移金属水酸化物及び/又はアルミニウム水酸化物を1:1.5〜3:1の量の金属水酸化物対未硬化フェノール系樹脂の比で含む、未硬化材料が提供される。
−未硬化フェノール系樹脂と、
−フィラーと
から本質的になり、フィラーが、2.5:1以上の量のフィラー対未硬化フェノール系樹脂の比で存在し、さらにフィラーが、遷移金属水酸化物及び/又はアルミニウム水酸化物を1:1.5〜3:1の量の金属水酸化物対未硬化フェノール系樹脂の比で含む、未硬化材料を提供する。
−未硬化フェノール系樹脂と、
−フィラーと、
−任意で、本明細書に具体的に記載の別の添加剤と
からなり、フィラーが、2.5:1以上の量のフィラー対未硬化フェノール系樹脂の比で存在し、フィラーが、遷移金属水酸化物及び/又はアルミニウム水酸化物を1:1.5〜3:1の量の金属水酸化物対未硬化フェノール系樹脂の比で含む、未硬化材料を提供する。
i.本明細書に上述の未硬化材料を用意するステップと、
ii.未硬化材料をシートに成形するステップと
を含む方法が提供される。
i.本明細書に上述の未硬化材料を用意するステップと、
ii.本明細書に上述の繊維を層の形態で用意するステップと、
iii.未硬化材料の層を繊維に付与するステップと
を含む。
・より良い温度性能及び熱衝撃回復力(thermal shock resilience)
○本発明のフェノール系材料を使用して、ブレーキパッド、鋳型、航空宇宙用熱シールドなどを生成することができる。
・化学薬品、腐食性物質/溶媒、油及び水/塩水(酸性雨を含む)に対する優れた耐性
○本発明のフェノール系材料を使用して、実験台を製造することができる
・改善された防火性能、防煙性能及び毒性性能
○本発明のフェノール系材料は、大量輸送及び防護用途において使用することができる
・改善された抗菌特性
・より硬く、より強く、優れた寸法安定性
・電気抵抗
・良好な断熱
・優れた作業性
・低温加工
i.本明細書に上述の未硬化フェノール系樹脂材料又は本明細書に上述の未硬化フェノール系樹脂シートを用意するステップと、
ii.基材を用意するステップと、
iii.未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの層を基材の表面上に付与するステップと、
iv.未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの少なくとも一部が基材に結合するように、未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの層を基材にプレスするステップと
を含む方法が提供される。
i.基材を用意するステップと、
ii.繊維、例えば本明細書に上述の繊維の層を用意するステップと、
iii.本明細書に上述の未硬化フェノール系樹脂材料を提供するステップと、
iv.繊維を基材の表面に付与するステップと、
v.未硬化フェノール系樹脂材料の層を繊維上に付与するステップと、
vi.複合材を形成するように未硬化フェノール系樹脂材料及び繊維を基材にプレスするステップと
を含み得る。
i.本明細書に上述の未硬化フェノール系樹脂材料又は本明細書に上述の未硬化フェノール系樹脂シートの層を用意するステップと、
ii.未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの層を硬化するステップと
を含む方法を対象とする。
本実施例では、本発明に従って製造することができるフェノール系樹脂のカラーバリエーション及び強度の両方について、先行技術のSMC化合物と比較して説明する。
この例では、本発明によるフェノール系材料の代わりに、市販のSMCを使用した。より具体的には、Menzolit(登録商標)SMC 0650の3mm厚のシートを使用した。
Claims (56)
- フェノール系樹脂シートを形成するための未硬化材料であって、
−未硬化フェノール系樹脂と、
−フィラーと、
−前記フェノール系樹脂の含有量に対して2wt.%未満の量の触媒と
を含み、前記フィラーが、2.5:1以上の量のフィラー対未硬化フェノール系樹脂の比で存在し、さらに前記フィラーが、遷移金属水酸化物及び/又はアルミニウム水酸化物を1:1.5〜3:1の量の金属水酸化物対未硬化フェノール系樹脂の比で含む、前記未硬化材料。 - 触媒が、未硬化フェノール系樹脂の含有量に対して1wt.%未満の量で存在する、請求項1に記載の未硬化材料。
- 触媒が、未硬化フェノール系樹脂の含有量に対して0.5wt.%未満の量で存在する、請求項2に記載の未硬化材料。
- 触媒が、0.2wt.%未満の量で存在する、請求項3に記載の未硬化材料。
- 触媒を実質的に含まない、請求項4に記載の未硬化材料。
- 触媒を含まない、請求項5に記載の未硬化材料。
- フィラーが3:1以上の量で存在する、請求項1〜6のいずれかに記載の未硬化材料。
- フィラーが3.5:1以上の量で存在する、請求項7に記載の未硬化材料。
- フィラーが5:1以上の量で存在する、請求項8に記載の未硬化材料。
- フィラーが20:1以下の量で存在する、請求項1〜9のいずれかに記載の未硬化材料。
- フェノール系樹脂がフェノール−ホルムアルデヒド樹脂である、請求項1〜10のいずれかに記載の未硬化材料。
- フィラーが、未硬化材料に不溶の粒子状固体である、請求項1〜11のいずれかに記載の未硬化材料。
- フィラーが、残りの未硬化材料に対して不活性である、請求項1〜12のいずれかに記載の未硬化材料。
- フィラーが無機材料である、請求項1〜13のいずれかに記載の未硬化材料。
- フィラーが、粘土、粘土鉱物、タルク、バーミキュライト、金属酸化物、耐火物、中実若しくは中空ガラスマイクロスフェア、フライアッシュ、炭塵、木粉、穀粉、堅果殻粉、シリカ、粉末形態の粉砕されたプラスチック及び樹脂、粉末状回収廃プラスチック、粉末状樹脂、顔料並びにデンプンのうちの1又は2以上から選択される、請求項1〜14のいずれかに記載の未硬化材料。
- 遷移金属水酸化物又はアルミニウム水酸化物が式M(OH)3(式中、Mは金属である)のものである、請求項1〜15のいずれかに記載の未硬化材料。
- 金属Mが、スカンジウム、バナジウム、クロム、マンガン、鉄、コバルト及びアルミニウムのうちの1又は2以上から選択され得る、請求項16に記載の未硬化材料。
- 金属水酸化物がアルミニウム水酸化物である、請求項1〜17のいずれかに記載の未硬化材料。
- 金属水酸化物対未硬化フェノール系樹脂の量の比が1:1.6〜2.5:1である、請求項1〜18のいずれかに記載の未硬化材料。
- 金属水酸化物対未硬化フェノール系樹脂の量の比が1:2〜2:1である、請求項19に記載の未硬化材料。
- フィラーが、アルカリ金属のケイ酸塩及び/又は炭酸塩を実質的に含まない、請求項15〜20のいずれかに記載の未硬化材料。
- 顔料が、金属酸化物、粉末状塗料、岩石粉末及び砂のうちの1又は2以上から選択される、請求項15〜21のいずれかに記載の未硬化材料。
- 材料が粘度調整剤をさらに含む、請求項1〜22のいずれかに記載の未硬化材料。
- 粘度調整剤が、ブタノール、クロロホルム、エタノール、水、アセトニトリル、ヘキサン及びイソプロピルアルコールから選択される、請求項23に記載の未硬化材料。
- 繊維をさらに含む、請求項1〜24のいずれかに記載の未硬化材料。
- 繊維が織られている、又は織られていない、請求項25に記載の未硬化材料。
- 繊維が層の形態である、請求項25又は26に記載の未硬化材料。
- 繊維がマット又はファブリックの形態である、請求項27に記載の未硬化材料。
- 繊維が、鉱物繊維(細断されたガラス繊維及び細分された石綿など)、チョップド繊維、細断された天然又は合成繊維並びに繊維の形態の粉砕されたプラスチック及び樹脂のうちの1又は2以上から選択される、請求項25〜28のいずれかに記載の未硬化材料。
- 繊維が、炭素繊維、ガラス繊維及びアラミド繊維のうちの1又は2以上から選択される、請求項29に記載の未硬化材料。
- 繊維が、6:1〜1:3の樹脂対繊維の比で未硬化材料に加えられる、請求項25〜30のいずれかに記載の未硬化材料。
- 比が4:1〜1:1である、請求項31に記載の未硬化材料。
- 未硬化フェノール系樹脂シートを形成する方法であって、
i.請求項1〜32のいずれかに記載の未硬化材料を用意するステップと、
ii.前記未硬化材料をシートに成形するステップと
を含む、前記方法。 - 成形するステップが加圧を伴う、請求項33に記載の方法。
- 未硬化フェノール系樹脂シートを形成する方法であって、
i.請求項1〜24のいずれかに記載の未硬化材料を用意するステップと、
ii.請求項25〜32のいずれかに記載の繊維を層の形態で用意するステップと、
iii.前記未硬化材料の層を前記繊維に付与するステップと
を含む、前記方法。 - 未硬化材料を付与するステップが加圧をさらに含む、請求項35に記載の方法。
- 請求項33〜36のいずれかに記載の方法により製造される未硬化フェノール系樹脂シート。
- 請求項1〜32のいずれかに記載の未硬化材料から製造される未硬化フェノール系樹脂シート。
- 複合材製品を生成する方法であって、
i.請求項1〜32のいずれかに記載の未硬化フェノール系樹脂材料又は請求項37若しくは38に記載の未硬化フェノール系樹脂シートを用意するステップと、
ii.基材を用意するステップと、
iii.前記未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの層を前記基材の表面上に付与するステップと、
iv.前記未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの少なくとも一部が前記基材に結合するように、前記未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの前記層を前記基材にプレスするステップと
を含む、方法。 - 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの少なくとも部分的なセットを引き起こす又は可能にするステップをさらに含む、請求項39に記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの少なくとも部分的なセットを引き起こす又は可能にするステップが、前記未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートを適切な温度まで加熱するステップを含む、請求項40に記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートが、少なくとも50℃の温度まで加熱される、請求項41に記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートが、100〜200℃の間の温度まで加熱される、請求項41又は42に記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートが、少なくとも1分間加熱される、請求項39〜43のいずれかに記載の方法。
- 基材が連続気泡発泡体であり、プレスステップの間、未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの少なくとも一部が前記基材に流れ込む、請求項39〜44のいずれかに記載の方法。
- 連続気泡発泡体基材が、発泡フェノール系樹脂又は発泡ポリウレタン樹脂から選択される、請求項45に記載の方法。
- 連続気泡発泡体基材が発泡フェノール系樹脂である、請求項46に記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートが、実質的にすべての連続気泡発泡体基材に付与される、請求項39〜47のいずれかに記載の方法。
- 未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートの層を基材にプレスするステップの前に、前記基材が成形される、請求項39〜48のいずれかに記載の方法。
- 少なくとも400Paの圧力がプレス中に加えられる、請求項39〜49のいずれかに記載の方法。
- 500〜7,000Paの間の圧力が未硬化フェノール系樹脂材料又は未硬化フェノール系樹脂シートに加えられる、請求項50に記載の方法。
- 加圧中、基材の表面が成型されるように、連続気泡発泡体基材がクラッシャブル材料である、請求項39〜51のいずれかに記載の方法。
- 請求項39〜52のいずれかに記載の方法により生成される製品。
- 連続気泡発泡体基材と、前記基材の表面に結合されたフェノール系樹脂の表皮とを含む製品であって、前記フェノール系樹脂が請求項1〜32のいずれかに記載の通りである、前記製品。
- 着色樹脂表皮を形成するためのフェノール系樹脂ペーストの使用であって、前記フェノール系樹脂が請求項1〜32のいずれかに記載の通りである、前記使用。
- 樹脂表皮が白色、黄色、ピンク色、赤色、オレンジ色、緑色、青色又は紫色である、請求項55に記載の使用。
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