JP5932816B2 - オーバーモールド成形ポリアミド複合構造体及びその製造方法 - Google Patents
オーバーモールド成形ポリアミド複合構造体及びその製造方法 Download PDFInfo
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- JP5932816B2 JP5932816B2 JP2013536804A JP2013536804A JP5932816B2 JP 5932816 B2 JP5932816 B2 JP 5932816B2 JP 2013536804 A JP2013536804 A JP 2013536804A JP 2013536804 A JP2013536804 A JP 2013536804A JP 5932816 B2 JP5932816 B2 JP 5932816B2
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- Prior art keywords
- resin composition
- component
- polyamides
- polyamide
- composite structure
- 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.)
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Description
下記の材料が、実施例及び比較例に使用した組成物に含まれる。
実施例(表1及び2で「E」と略記)に使用した樹脂組成物及び比較例(表1及び2で「C」と略記)に使用した樹脂組成物を、二軸押出機中で構成要素を溶融又は溶融ブレンドすることにより製造した。押出機を出ると同時に、表1及び2に列記された組成物を、C1、E1、E2、E3、及びC2のマトリックス樹脂組成物並びにC1、E3、及びC2の表面樹脂組成物の場合には約102ミクロンの厚さのフィルムに、実施例E1及びE2の表面樹脂組成物の場合には約200ミクロンの厚さのフィルムにキャストした。
表1のオーバーモールド成形複合構造C1、E1、及びE2並びに表2のE3及びC2の製造に使用した複合構造を、厚さが約102ミクロンであり、C1、E1、E2、及びC2の場合にはPA1でできているフィルム、又はE3の場合にはマトリックス樹脂及び表面樹脂組成物でできているフィルムの8層と連続ガラス繊維織布の3層(直径17ミクロン、0.4%シラン系サイジング、公称ロービングテックス1200g/kmのE−ガラス繊維、2/2綾織り(バランス織り)に織られ、目付が600g/m2)と重ねることにより最初にラミネートを作ることにより製造した。下記のシーケンスをC1、E1、E2、及びC2に利用した、すなわち、PA1でできている2層、連続ガラス繊維織布の1層、PA1の2層、連続ガラス繊維織布の1層、PA1の2層、連続ガラス繊維織布の1層、及びPA1の2層。下記のシーケンスをE3に利用した、すなわち、表面樹脂組成物の2層(表2に記載)、連続ガラス繊維織布の1層、マトリックス樹脂組成物の2層(表2に記載)、連続ガラス繊維織布の1層、マトリックス樹脂組成物の2層、連続ガラス繊維織布の1層、及び表面樹脂組成物の2層。
表1及び2に列記されたオーバーモールド成形複合構造を、上述のとおり得られた複合構造の上に、約1.7mmのオーバーモールド成形用樹脂組成物をオーバー射出成形することにより製造した。
上述のとおり製造したオーバーモールド成形複合構造E1、E2、及びC1の5×5インチの試験片を、3/4インチ×5インチの試験片(約19mm×約127mm)に切り出し、オーバーモールド成形された部品を、オーバーモールド成形された部品と複合構造との界面まで切ることにより、切込みを入れた。切込みは、試験片のほぼ中心(長手方向)でその幅にわたっていれた。複合構造へのオーバーモールド成形された樹脂組成物の結合強度は、ISO−178を変更した三点曲げ法により、切込みを入れた試験片に対して測定した。装置及び幾何的形状はISO法178に準拠し、負荷用エッジをスパンの中心にして2.0インチ(約51mm)の支点幅で試験片を曲げる。試験片のオーバーモールド成形された部品は引張側(外側スパン)で2つの両端支点(2インチ(約51mm)離れている)に載っており、1つの支点(負荷)により、試験片の複合構造面にある圧縮側(内部スパン)でへこんだ。この試験形状では、試験片の切込みは下向きであった(引張側)。切込みは、中心から1/4インチ外して(負荷から1/4インチ離れて)置いた。試験は、2mm/分で、1KNの負荷により実施した。試験は、試験片の2つの部品の間に分離又は破断(層間剥離)が見られるまで実施した。その点での応力を記録した。表1において、本発明に従って製造した実施例E1及びE2が、比較例C1よりも高い結合強度を示すことが分かる。表1において、本発明による最も好ましい組成物により製造された実施例E2が、本発明による好ましい組成物により製造された実施例E1よりさらに高い結合強度を有することもさらに分かる。
上述のとおり製造したオーバーモールド成形複合構造E3及びC2の5×5インチの試験片を、オーバーモールドされた樹脂の流れ方向に沿って、3/4インチ×5インチの試験片(約19mm×約127mm)に切り出した。曲げ強さを、ISO−178三点曲げ法により、試験片に対して測定した。装置及び幾何的形状はISO法178に準拠し、負荷用エッジをスパンの中心にして2.0インチ(約51mm)の支点幅で試験片を曲げた。試験片の複合構造部品は引張側(外側スパン)で2つの両端支点(2インチ(約51mm)離れている)に載っており、1つの支点(負荷)により、試験片のオーバーモールドされた部品の面にある圧縮側(内部スパン)でへこんだ。試験は、2mm/分で、1KNの負荷により実施した。試験は、破断まで実施した。その点での応力を記録した。
1.i)表面を有する第一成分であって、前記表面の少なくとも一部分が表面樹脂組成物でできており、不織構造物、織物、繊維詰め物、及びこれらの組み合わせから選択される繊維状材料を含み、前記繊維状材料がマトリックス樹脂組成物により含浸されている第一成分と、
ii)オーバーモールド成形用樹脂組成物を含む第二成分とを含み、
前記第二成分が、前記第一成分の表面の少なくとも一部分の上で、前記第一成分に接着しており、かつ
前記表面樹脂組成物が、(A)230℃未満の融点を有するグループ(I)のポリアミドから選択される1種以上の全脂肪族ポリアミドと(B)少なくとも250℃の融点を有するグループ(II)のポリアミドから選択される1種以上の全脂肪族ポリアミドとのブレンドを含むポリアミド組成物から選択され、前記マトリックス樹脂組成物が、(B)から独立に選択されるか、又は(A)と(B)とのブレンドから独立に選択される、オーバーモールド成形複合構造体。
2.前記オーバーモールド成形用樹脂組成物が、(A)230℃未満の融点を有するグループ(I)のポリアミドから選択される1種以上の全脂肪族ポリアミドと(B)少なくとも250℃の融点を有するグループ(II)のポリアミドから選択される1種以上の全脂肪族ポリアミドとのブレンドを含むポリアミド組成物から選択されるか、又は少なくとも250℃の融点を有するグループ(II)のポリアミド(B)から選択されるポリアミドのみから選択される、前記1に記載のオーバーモールド成形複合構造体。
3.前記繊維状材料が、ガラス繊維、炭素繊維、アラミド繊維、天然繊維、又はこれらの組み合わせでできている、前記1又は2に記載のオーバーモールド成形複合構造体。
4.前記繊維状材料がガラス繊維でできている、前記3に記載のオーバーモールド成形複合構造体。
5.前記繊維状材料が、前記複合構造体の30体積パーセント〜60体積パーセントである、前記1〜4のいずれかに記載の複合構造体。
6.熱安定剤、酸化安定剤、強化剤、及び難燃剤、又はこれらの組み合わせからなる群から選択される1種以上の添加剤をさらに含む、前記1〜5のいずれかに記載の複合構造体。
7.グループ(I)のポリアミドから選択される前記1種以上の全脂肪族ポリアミドが、PA6、PA510、PA512、PA6/66、PA6/610、PA6/612、PA613、PA615、PA6/66/610、PA6/66/612、PA6/66/610/612、PAD6/66、PA1010、PA1012、PA11、PA12、PA612、PA1212からなる群から選択される、前記1〜6のいずれかに記載の複合構造体。
8.グループ(II)のポリアミドから選択される前記1種以上の全脂肪族ポリアミドが、PA66、PA6/66、PA6/66/610、PA6/66/612、PA6/66/610/612、PAD6/66、PA46からなる群から選択される、前記1〜7のいずれかに記載の複合構造体。
9.前記マトリックスポリアミド組成物の、グループ(I)のポリアミドから選択される前記1種以上のポリアミド(A)と、グループ(II)のポリアミドから選択される前記1種以上のポリアミド(B)との重量比(A:B)が、約1:99〜約95:5である、前記1〜8のいずれかに記載のオーバーモールド成形複合構造体。
10.前記マトリックスポリアミド組成物の、グループ(I)のポリアミドから選択される前記1種以上のポリアミド(A)と、グループ(II)のポリアミドから選択される前記1種以上のポリアミド(B)との重量比(A:B)が、約20:80〜約30:70であり、前記表面ポリアミド組成物の、グループ(I)のポリアミドから選択される前記1種以上のポリアミド(A)と、グループ(II)のポリアミドから選択される前記1種以上のポリアミド(B)との重量比(A:B)が、約40:60〜約60:40である、前記1〜9のいずれかに記載のオーバーモールド成形複合構造体。
11.前記マトリックス樹脂組成物が、グループ(II)のポリアミドから選択される1種以上のポリアミド(B)を含み、前記表面ポリアミド組成物の、グループ(I)のポリアミドから選択される前記1種以上のポリアミド(A)と、グループ(II)のポリアミドから選択される前記1種以上のポリアミド(B)との重量比(A:B)が、約40:60〜約60:40である、前記1〜10のいずれかに記載のオーバーモールド成形複合構造体。
12.(A)が、PA6、PA6/12、PA10/10を、単独又はこれらの組み合わせで含む、前記1〜11のいずれかに記載の複合構造体。
13.(B)が、PA66、PA46を、単独又はこれらの組み合わせで含む、前記1〜12のいずれかに記載の複合構造体。
14.自動車、トラック、民間飛行機、航空宇宙、レール、家電製品、コンピューターハードウェア、ハンドヘルドデバイス、レクリエーション及びスポーツ用の部品、機械の構造部品、建築物の構造部品、太陽光発電装置の構造部品、又は機械的装置の構造部品の形態である、前記1〜13のいずれかに記載のオーバーモールド成形複合構造体。
15.第一成分の上に、オーバーモールド成形用樹脂組成物を含む第二成分をオーバーモールド成形する工程を含む、オーバーモールド成形複合構造体を製造する方法であって、
前記第一成分が繊維状材料を含み、表面を有し、前記表面はその少なくとも一部分が表面樹脂組成物でできており、前記繊維状材料が、不織構造物、織物、繊維詰め物、及びこれらの組み合わせから選択され、前記繊維状材料がマトリックス樹脂組成物により含浸されており、前記第二成分が、前記第一成分の表面の少なくとも一部分の上で前記第一成分に接着しており、前記表面樹脂組成物が、(A)230℃未満の融点を有するグループ(I)のポリアミドから選択される1種以上の全脂肪族ポリアミドと(B)少なくとも250℃の融点を有するグループ(II)のポリアミドから選択される1種以上の全脂肪族ポリアミドとのブレンドを含むポリアミド組成物から選択され、前記マトリックス樹脂組成物が、(B)から独立に選択されるか、又は(A)と(B)とのブレンドから独立に選択される、オーバーモールド成形複合構造体を製造する方法。
16.前記含浸工程より後であるが前記オーバーモールド成形工程より前に起こる、前記第一成分を付形する工程をさらに含む、前記15に記載の方法。
17.前記第一成分が、前記オーバーモールド成形工程の前に加熱されて、前記オーバーモールド成形用樹脂組成物との界面を形成する表面が軟化又は部分的に溶融される、前記15又は16に記載の方法。
18.前記第一成分が、前記オーバーモールド成形工程の前に加熱されない、前記15〜17のいずれかに記載の方法。
Claims (2)
- i)表面を有する第一成分であって、前記表面の少なくとも一部分が表面樹脂組成物でできており、不織構造物、織物、繊維詰め物、及びこれらの組み合わせから選択される繊維状材料を含み、前記繊維状材料がマトリックス樹脂組成物により含浸されている第一成分と、
ii)オーバーモールド成形用樹脂組成物を含む第二成分とを含み、
前記第二成分が、前記第一成分の表面の少なくとも一部分の上で、前記第一成分に接着しており、かつ
前記表面樹脂組成物が、(A)230℃未満の融点を有するグループ(I)のポリアミドから選択される1種以上の全脂肪族ポリアミドと(B)少なくとも250℃の融点を有するグループ(II)のポリアミドから選択される1種以上の全脂肪族ポリアミドとのブレンドを含むポリアミド組成物から選択され、前記マトリックス樹脂組成物が、(B)から独立に選択されるか、又は(A)と(B)とのブレンドから独立に選択され、前記オーバーモールド成形用樹脂組成物が、全脂肪族ポリアミドを含む、オーバーモールド成形複合構造体。 - 第一成分の上に、オーバーモールド成形用樹脂組成物を含む第二成分をオーバーモールド成形する工程を含む、オーバーモールド成形複合構造体を製造する方法であって、
前記第一成分が繊維状材料を含み、表面を有し、前記表面はその少なくとも一部分が表面樹脂組成物でできており、前記繊維状材料が、不織構造物、織物、繊維詰め物、及びこれらの組み合わせから選択され、前記繊維状材料がマトリックス樹脂組成物により含浸されており、前記第二成分が、前記第一成分の表面の少なくとも一部分の上で前記第一成分に接着しており、前記表面樹脂組成物が、(A)230℃未満の融点を有するグループ(I)のポリアミドから選択される1種以上の全脂肪族ポリアミドと(B)少なくとも250℃の融点を有するグループ(II)のポリアミドから選択される1種以上の全脂肪族ポリアミドとのブレンドを含むポリアミド組成物から選択され、前記マトリックス樹脂組成物が、(B)から独立に選択されるか、又は(A)と(B)とのブレンドから独立に選択され、前記オーバーモールド成形用樹脂組成物が、全脂肪族ポリアミドを含む、オーバーモールド成形複合構造体を製造する方法。
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