JP6149579B2 - Winding product - Google Patents

Description

  The present invention relates to a wound product obtained by winding a composite material including a polyamide resin and continuous fibers around a core material.

Conventionally, composite materials including polyamide resin and continuous fibers have been widely studied. Such composite materials are widely used for fiber-reinforced resin molded products. Here, when the composite material is tape-shaped, the composite material is usually wound around a core material and transported.
In Patent Document 1, a carbon fiber tape made of a composite containing carbon fiber and an aromatic polyamide resin or an aliphatic polyamide resin is a carbon fiber wound tape wound around a cylindrical core material, from the formula (I) The required width (W) of the carbon fiber tape is in the range of 5 to 100 mm, and the minimum diameter (D) of the cylindrical core member around which the carbon fiber tape having the width (W) in the range of 5 to 100 mm is wound, A carbon fiber-wrapped tape that is obtained from the formula (II) is disclosed.
0.2 × 10 ⁻³ × N ≦ W ≦ 2 × 10 ⁻³ × N (I)
(In formula (I), N is the number of carbon fibers constituting the carbon fiber.)
4.5 × F × t ≦ D ≦ 50 × F × t (II)
(In Formula (II), F is the amount of carbon fiber and is in the range of 20 to 60% by mass, and t is the thickness of the carbon fiber tape and is in the range of 0.1 to 0.5 mm.)

International Publication WO2012 / 002410 Pamphlet

Here, when this inventor examined patent document 1, in patent document 1, although the width | variety of a carbon fiber tape (composite material) is as thin as 5-100 mm, when this width becomes wide, it will wind up It was found that wrinkles and unevenness occurred at the time, and it was difficult to wind up properly. Furthermore, it was found that a so-called curl when using a wound product is large, and problems such as deterioration of workability thereafter occur.
The present invention aims to solve such a problem, and is a wound product obtained by winding a composite material including a polyamide resin and continuous fibers. It is an object of the present invention to provide a wound product that is suppressed and is difficult to be wound.

As a result of intensive studies by the inventor under the above problems, it has been found that the above problems can be solved by the following means <1>, preferably <2> to <10>.
<1> A wound product obtained by winding a composite material (C) including a polyamide resin (A) and continuous fibers (B) around a core material,
A rolled article satisfying the following formula, in which the contact angle θ with respect to water of the composite material (C) is 60 to 82 °, the width d is more than 100 mm and not more than 3000 mm.
Formula: 200 ≦ D / t ≦ 3000
(In the above formula, D represents the outer diameter (unit: mm) of the core material, and t represents the thickness (unit: mm) of the composite material (C).)
<2> The polyamide resin (A) is a polycondensate of a diamine compound and a dicarboxylic acid compound, and 50 mol% or more of the diamine compound includes an XD-type polyamide resin that is xylylenediamine. The wound product described.
<3> The wound product according to <2>, further including an aliphatic polyamide resin as the polyamide resin (A).
<4> The wound product according to <2> or <3>, wherein the xylylenediamine is metaxylylenediamine and / or paraxylylenediamine.
<5> The number average molecular weight (Mn) of the XD-based polyamide resin is 6,000 to 30,000, and the amount of the component having a molecular weight of 1000 or less in the polyamide resin is 0.5 to 5 mass. %, The wound product according to any one of <2> to <4>.
<6> The wound product according to any one of <1> to <5>, wherein an outer diameter of the core material is 60 to 350 mm.
<7> The wound product according to any one of <1> to <6>, wherein the composite material (C) has a thickness of 0.05 to 2 mm.
<8> The wound product according to any one of <1> to <7>, wherein the ratio of the continuous fiber (B) in the composite material (C) is 10 to 65% by mass.
<9> The wound product according to any one of <1> to <8>, wherein a weight per 1 m ² of the composite material (C) is 50 to 3000 g.
<10> The wound product according to any one of <1> to <9>, wherein a width d of the composite material (C) is 120 to 2000 mm.

  A composite material including a polyamide resin and continuous fibers, which is a wide composite material that is wound while suppressing generation of wrinkles and unevenness, can be provided.

It is a figure for demonstrating the measuring method of a contact angle.

  Hereinafter, the contents of the present invention will be described in detail. In the present specification, “to” is used to mean that the numerical values described before and after it are included as a lower limit value and an upper limit value.

The wound product of the present invention is a wound product obtained by winding a composite material (C) containing a polyamide resin (A) and continuous fibers (B) around a core material, and the contact of the composite material (C) with water. The angle θ is 60 to 82 °, the width d is more than 100 mm and not more than 3000 mm, and the wound product satisfies the following formula.
Formula: 200 ≦ D / t ≦ 3000
(In the above formula, D represents the outer diameter (unit: mm) of the core material, and t represents the thickness (unit: mm) of the composite material (C).)
By adopting such a configuration, even in the case of a wide composite material (C) having a width d exceeding 100 mm, generation of wrinkles can be suppressed and winding can be performed without unevenness. As a result of studies by the present inventor, when the composite material (C) absorbs moisture, the composite material (C) is swollen and unevenness and wrinkles are likely to occur. Therefore, it is conceivable to increase the contact angle of the composite material (C) with water. On the other hand, when the contact angle of the composite material (C) with respect to water becomes too large, static electricity is likely to be generated, and the composite material (C) is likely to entrain dust and easily causes a problem in product quality. In addition, it tends to be prone to winding. In addition, depending on the outer diameter of the core material and the thickness of the composite material (C), wrinkles and unevenness are more likely to occur due to curling or absorption of moisture in the composite material (C) or dust due to static electricity. There is a case. In the present invention, the wide composite material (C) was successfully wound up by appropriately adjusting the contact angle with respect to D / t and water.
The configuration of the present invention will be described below.

  The composite (C) used in the present invention has a width d of preferably 120 to 2500 mm, more preferably 120 to 2000 mm, and further preferably 150 to 1500 mm. Within this range, the molding process and handling are easier and preferable.

The composite material (C) used in the present invention preferably has a water contact angle of 62 to 80 °, more preferably 65 to 78 °, and more preferably 68 to 77 °. By setting it as such a range, it can be set as a more appropriate wound product. In addition, it is difficult to be affected by the moisture content in the atmosphere, that is, it is possible to perform production with stable generation of wrinkles and unevenness regardless of relative humidity.
The method for making the composite material (C) used in the present invention have a predetermined contact angle is not particularly defined, but can be adjusted by the type of polyamide resin described later, additives added to the resin, and the like. Examples of the additive include silicon-based resins, fluorine-based resins, and surfactants.
The contact angle in the present invention can employ the θ / 2 method. That is, as shown in FIG. 1, when the shape of the water droplet is assumed to be a part of a sphere, the angle θ with respect to the solid surface of the tangent line 1 from the left and right end points of the water droplet is obtained, and the radius r and height h of the sphere are obtained. The contact angle can be obtained by substituting into the following equation. Further, in the θ / 2 method, the angle θ ₁ of the straight line connecting the left and right end points of the water droplet and the vertex 2 with respect to the solid surface is obtained, and the contact angle can be obtained by doubling this angle.

  The contact angle θ with respect to water of the composite material (C) can be measured according to JIS R3257 using a contact angle meter DM500 manufactured by Kyowa Interface Science Co., Ltd. Specifically, a sample is cut out from the composite material (C) into a sheet shape, and the contact angle 20 seconds after water contacts the surface of the sample placed horizontally is measured against the composite material (C). The contact angle θ can be obtained. The sample cut out from the composite material (C) used for this test is used after being conditioned for 1 hour under conditions of 23 ° C. and 50% relative humidity before the test.

Furthermore, in the wound product of the present invention, the thickness t of the composite material (C) and the outer diameter D of the core material satisfy the following requirements.
Formula: 200 ≦ D / t ≦ 3000
(In the above formula, D represents the outer diameter (unit: mm) of the core material, and t represents the thickness (unit: mm) of the composite material (C).)
In the present invention, when the thickness of the composite material (C) and the core material to be wound satisfy the above relationship, curling is difficult to occur, and generation of unevenness and wrinkles can be suppressed and winding can be appropriately performed. In the present invention, it is preferable to satisfy 300 ≦ D / t ≦ 2000, more preferably 320 ≦ D / t ≦ 2000, still more preferably 500 ≦ D / t ≦ 1800, and 1000 ≦ D / t. It is particularly preferable that t ≦ 1600 is satisfied. In a known wound product, D / t is usually estimated to be a numerical value of about 1 to 2 digits. In the present invention, by increasing the value of D / t, a wide composite material is obtained. Successful winding of (C) is successful.

  The thickness t of the composite material (C) used in the present invention is preferably 0.01 to 5.0 mm, more preferably 0.05 to 2.0 mm, and 0.05 to 1.0 mm. More preferably, 0.05 to 0.3 mm is particularly preferable. By setting it as such a range, it can be set as a more appropriate wound product.

  The outer diameter D of the core material used in the present invention is preferably 60 to 350 mm, and more preferably 75 to 310 mm. By setting it as such a range, it can be set as a more appropriate wound product.

The weight per 1 m ² of the composite material (C) used in the present invention is preferably 50 to 3000 g, more preferably 50 to 1000 g, still more preferably 60 to 500 g, and 70 to Particularly preferred is 200 g. By setting it as such a range, it can be set as a more appropriate wound product.

  Next, the detail of the material of the composite material (C) used by this invention is described. The composite material (C) used in the present invention is preferably a composite material (C) formed by impregnating the continuous resin (B) with the polyamide resin (A).

<Polyamide resin>
The polyamide resin in the present invention is a polyamide polymer having an acid amide group (—CONH—) in the molecule and capable of being melted by heating. Specifically, various polyamide resins such as a lactam polycondensate, a polycondensate of a diamine compound and a dicarboxylic acid compound, a polycondensate of ω-aminocarboxylic acid, or a copolymerized polyamide resin or blend thereof. It is. Therefore, the polyamide resin (A) used in the present invention may be one type or two or more types.

  Specific examples of polyamide resins obtained by polycondensation from these raw materials include polyamide 4, polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 56, polyamide 66, polyamide 610, polyamide 612, polyhexamethylene terephthalamide. (Polyamide 6T), polyhexamethylene isophthalamide (polyamide 6I), polymetaxylylene adipamide (polyamide MXD6), polymetaxylylene decanamide, polyamide 9T, polyamide 9MT, and the like. In the present invention, these polyamide homopolymers or copolymers can be used alone or in the form of a mixture.

Among these, an XD polyamide resin, which is a polycondensate of a diamine compound and a dicarboxylic acid compound and 50 mol% or more of the diamine compound is xylylenediamine, is preferable. In the XD polyamide resin, xylylenediamine is XD type polyamide resin which is metaxylylenediamine and / or paraxylylenediamine is more preferable.
Even more preferably, the XD-based polyamide resin used in the present invention is at least 70 mol%, more preferably at least 80 mol% of the diamine compound is metaxylylenediamine and / or paraxylylenediamine, and is preferably a dicarboxylic acid compound. Is a diamine compound and a dicarboxylic acid which is an α, ω-linear aliphatic dicarboxylic acid having 50 mol% or more, more preferably 70 mol% or more, particularly 80 mol% or more, preferably 4 to 20 carbon atoms. Polycondensates with compounds are preferred.
Metaxylylenediamine and paraxylylenediamine can be mixed and used in any proportion, but when heat resistance is important, 0 to 50 mol% of metaxylylenediamine and 50 to 100 mol% of paraxylenediamine are preferable. When emphasizing the molding processability of the polyamide resin film described later, 50 to 100 mol% of metaxylylenediamine and 0 to 50 mol% of paraxylenediamine are preferable.

Examples of diamines other than metaxylylenediamine and paraxylylenediamine that can be used as a raw material diamine component of the XD polyamide resin include tetramethylenediamine, pentamethylenediamine, 2-methylpentanediamine, hexamethylenediamine, heptamethylenediamine, Aliphatic diamines such as octamethylenediamine, nonamethylenediamine, decamethylenediamine, dodecamethylenediamine, 2,2,4-trimethyl-hexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, 1,3-bis ( Aminomethyl) cyclohexane, 1,4-bis (aminomethyl) cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis (4-aminocyclohexyl) methane, 2,2-bi Alicyclic diamines such as (4-aminocyclohexyl) propane, bis (aminomethyl) decalin, bis (aminomethyl) tricyclodecane, bis (4-aminophenyl) ether, paraphenylenediamine, bis (aminomethyl) naphthalene, etc. The diamine etc. which have the following aromatic ring can be illustrated, and can be used 1 type or in mixture of 2 or more types.
When a diamine other than xylylenediamine is used as the diamine component, it is preferably 50 mol% or less of the diamine structural unit, more preferably 30 mol% or less, still more preferably 1 to 25 mol%, particularly Preferably it is used in a proportion of 5 to 20 mol%.

  Preferred examples of the α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms to be used as a raw material dicarboxylic acid component of the XD-based polyamide resin include succinic acid, glutaric acid, pimelic acid, suberic acid, azelaic acid, Aliphatic dicarboxylic acids such as adipic acid, sebacic acid, undecanedioic acid, and dodecanedioic acid can be exemplified, and one or a mixture of two or more can be used. Among these, the melting point of the polyamide resin is used for molding processing. Adipic acid or sebacic acid is preferable and sebacic acid is particularly preferable because it falls within an appropriate range.

  Examples of the dicarboxylic acid component other than the α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms include phthalic acid compounds such as isophthalic acid, terephthalic acid and orthophthalic acid, 1,2-naphthalenedicarboxylic acid, 3-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 1,6-naphthalenedicarboxylic acid, 1,7-naphthalenedicarboxylic acid, 1,8-naphthalenedicarboxylic acid, 2,3- Examples thereof include naphthalenedicarboxylic acid such as isomers such as naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and 2,7-naphthalenedicarboxylic acid, and one kind or a mixture of two or more kinds can be used.

  When a dicarboxylic acid other than an α, ω-linear aliphatic dicarboxylic acid having 4 to 20 carbon atoms is used as the dicarboxylic acid component, it is preferable to use isophthalic acid from the viewpoint of molding processability and barrier properties. The proportion of isophthalic acid is preferably 30 mol% or less, more preferably 1 to 30 mol%, particularly preferably 5 to 20 mol% of the dicarboxylic acid structural unit.

  Furthermore, in addition to the diamine component and the dicarboxylic acid component, as a component constituting the polyamide resin (A), lactams such as ε-caprolactam and laurolactam, aminocaproic acid, aminoundecanoic acid and the like as long as the effects of the present invention are not impaired. These aliphatic aminocarboxylic acids can also be used as copolymerization components.

  An example of a preferred embodiment of the polyamide resin (A) used in the present invention is an embodiment in which 90% by weight or more of the polyamide resin (A) is composed of an XD-based polyamide resin, but the polyamide resin (A) used in the present invention is preferable. Another example of the embodiment includes a mixture of an XD polyamide resin and an aliphatic polyamide resin. By using the XD polyamide resin and the aliphatic polyamide resin in combination, the surface appearance tends to be further improved. In this case, the preferable blending ratio (molar ratio) of the XD polyamide resin and the aliphatic polyamide resin is 5:95 to 95: 5, more preferably 10:90 to 90:10.

  In the above embodiment, the XD polyamide resin is an XD polyamide resin having a number average molecular weight (Mn) of 6,000 to 30,000, and the molecular weight of the XD polyamide resin is 1000 or less. A polyamide resin having an amount of 0.5 to 5% by mass is preferred.

  More preferably, the polyamide resin (A) is a polyamide resin having a number average molecular weight (Mn) of 6,000 to 30,000, and among these polyamide resins, the amount of a component having a molecular weight of 1000 or less is 0.00. It is a polyamide resin which is 5 to 5% by mass.

  By making the number average molecular weight (Mn) in the range of 6,000 to 30,000, the impregnation property of the polyamide resin (A) into the continuous fiber (B) is improved, and the strength of the resulting composite material (C) Tend to improve more. The number average molecular weight (Mn) is more preferably 8,000 to 28,000, still more preferably 9,000 to 26,000, still more preferably 10,000 to 24,000, and particularly preferably 11 2,000 to 22,000, more preferably 12,000 to 20,000. By setting it as such a range, it exists in the tendency for heat resistance, an elasticity modulus, dimensional stability, and moldability to improve more.

The number average molecular weight (Mn) referred to here is the following formula based on the terminal amino group concentration [NH ₂ ] (μ equivalent / g) and the terminal carboxyl group concentration [COOH] (μ equivalent / g) of the polyamide resin. Calculated.
Number average molecular weight (Mn) = 2,000,000 / ([COOH] + [NH ₂ ])

  Further, in the present invention, the polyamide resin (A) preferably contains 0.1 to 5% by mass of a polyamide resin component having a molecular weight of 1,000 or less. By blending 5% by mass or more, the polyamide resin (A) is excellent in impregnation into continuous fibers, and the strength and low warpage of the resulting composite material (C) tend to be further improved. By setting it as 5 mass% or less, it can suppress more effectively that a low molecular-weight polyamide resin component bleeds and intensity | strength deteriorates or a surface external appearance worsens.

  The content of the polyamide resin component having a molecular weight of 1,000 or less is preferably 0.1 to 4.5% by mass, more preferably 0.1 to 2% by mass, and still more preferably 0.1 to 1.%. 0% by mass.

  The content of the low molecular weight component having a molecular weight of 1,000 or less can be adjusted by adjusting the melt polymerization conditions such as the temperature and pressure during the polymerization of the XD polyamide resin and the diamine dropping rate. In particular, the inside of the reaction apparatus can be depressurized at the latter stage of the melt polymerization to remove low molecular weight components and adjusted to an arbitrary ratio. Alternatively, the low molecular weight polyamide resin component may be removed by hot water extraction of the polyamide resin produced by melt polymerization, or the low molecular weight polyamide resin component may be removed by solid phase polymerization under reduced pressure after the melt polymerization. Also good. In the solid phase polymerization, the low molecular weight polyamide resin component can be controlled to an arbitrary content by adjusting the temperature and the degree of reduced pressure. It can also be adjusted by adding a low molecular weight polyamide resin component having a molecular weight of 1,000 or less to the high molecular weight polyamide resin component later.

  In addition, the measurement of the amount of components having a molecular weight of 1,000 or less is based on a standard polymethyl methacrylate (PMMA) conversion value by gel permeation chromatography (GPC) measurement using “HLC-8320GPC” manufactured by Tosoh Corporation (TOSOH CORPORATION). Can be sought. As the measurement column, two “TSKgel SuperHM-H” were used, the solvent was hexafluoroisopropanol (HFIP) having a sodium trifluoroacetate concentration of 10 mmol / l, the resin concentration was 0.02% by mass, and the column temperature was It can be measured with a refractive index detector (RI) at 40 ° C., a flow rate of 0.3 ml / min. A calibration curve is prepared by dissolving 6 levels of PMMA in HFIP.

The XD polyamide resin used in the present invention preferably contains 0.01 to 1% by mass of a cyclic polyamide resin. In the present invention, the cyclic compound refers to a compound in which a salt composed of a diamine component and a dicarboxylic acid component, which are raw materials of the polyamide resin (A), forms a ring, and can be quantified by the following method.
The polyamide resin pellets are pulverized by an ultracentrifugation mill, passed through a sieve of φ0.25 mm, and 10 g of a powder sample of φ0.25 mm or less is measured on a cylindrical filter paper. Thereafter, Soxhlet extraction is performed with 120 ml of methanol for 9 hours, and the obtained extract is concentrated to 10 ml with care not to dry out with an evaporator. At this time, if the oligomer is precipitated, it is removed by appropriately passing through a PTFE filter. A solution obtained by diluting the obtained extract 50-fold with methanol is used for measurement, and quantitative analysis is performed by high-performance liquid chromatographic HPLC manufactured by Hitachi High-Technology Corporation to obtain a cyclic polyamide resin content. Ask for.
By containing the cyclic polyamide resin in such a range, the impregnation property to the continuous fiber (B) of the XD-based polyamide resin is excellent, and the strength of the obtained composite material (C) tends to be further improved. There is a tendency that warpage is reduced and dimensional stability is more likely to be improved. The more preferable content of the cyclic polyamide resin is 0.05 to 0.8% by mass, and further preferably 0.1 to 0.5% by mass.

  The XD polyamide resin produced by melt polymerization often contains a considerable amount of cyclic polyamide resin, and these are usually removed by hot water extraction or the like. By adjusting the degree of this hot water extraction, the amount of the cyclic polyamide resin can be adjusted. It is also possible to adjust the pressure during melt polymerization.

The polyamide resin (A) used in the present invention preferably has a molecular weight distribution (weight average molecular weight / number average molecular weight (Mw / Mn)) of 1.8 to 3.1. The molecular weight distribution is more preferably 1.85 to 2.8, still more preferably 1.9 to 2.7. By making molecular weight distribution into such a range, the impregnation property to the continuous fiber (B) of a polyamide resin (A) improves more, and it exists in the tendency which is easy to obtain the composite material (C) excellent in the mechanical characteristic.
The molecular weight distribution of the polyamide resin (A) can be adjusted, for example, by appropriately selecting the polymerization reaction conditions such as the type and amount of the initiator and catalyst used in the polymerization, the reaction temperature, pressure, and time. It can also be adjusted by mixing a plurality of types of polyamide resins having different average molecular weights obtained under different polymerization conditions or by separately precipitating the polyamide resins after polymerization.

  The molecular weight distribution can be determined by GPC measurement. Specifically, using “HLC-8320GPC” manufactured by Tosoh Corporation as a device and two “TSK gel Super HM-H” manufactured by Tosoh Corporation as columns, eluent Measured under conditions of hexafluoroisopropanol (HFIP) having a sodium trifluoroacetate concentration of 10 mmol / l, a resin concentration of 0.02% by mass, a column temperature of 40 ° C., a flow rate of 0.3 ml / min, and a refractive index detector (RI). It can obtain | require as a value of polymethylmethacrylate conversion. A calibration curve is prepared by dissolving 6 levels of PMMA in HFIP.

The polyamide resin (A) has a melt viscosity measured under the conditions that the melting point of the polyamide resin (A) is + 30 ° C., the shear rate is 122 sec ⁻¹ , and the moisture content of the XD polyamide resin is 0.06% by mass or less. 50 to 1200 Pa · s. By making melt viscosity into such a range, the impregnation property to the continuous fiber of a polyamide resin (A) becomes good. When the polyamide resin (A) has two or more melting points as described later, the measurement is performed with the temperature at the peak top of the endothermic peak on the high temperature side as the melting point.
The melt viscosity of the polyamide resin can be adjusted, for example, by appropriately selecting the charging ratio of the raw material dicarboxylic acid component and the diamine component, the polymerization catalyst, the molecular weight regulator, the polymerization temperature, and the polymerization time.

Moreover, it is preferable that the polyamide resin (A) has a bending elastic modulus retention rate of 85% or more at the time of water absorption. By setting the bending elastic modulus retention rate at the time of water absorption within such a range, the resulting composite material (C) is less likely to be deteriorated in physical properties under high temperature and high humidity, and the shape change such as warpage tends to be reduced.
Here, the bending elastic modulus retention rate at the time of water absorption refers to the bending elastic modulus at the time of water absorption of 0.5% by mass with respect to the bending elastic modulus at the time of water absorption of 0.1% by mass of the bending test piece made of the polyamide resin (A). It is defined as a ratio (%) of the modulus, and a high value means that the bending elastic modulus is not easily lowered even when moisture is absorbed.
The bending elastic modulus retention at the time of water absorption is more preferably 86% or more, and still more preferably 88% or more.
The flexural modulus retention rate at the time of water absorption of the polyamide resin can be controlled by, for example, the mixing ratio of paraxylylenediamine and metaxylylenediamine, and the higher the proportion of paraxylylenediamine, the better the flexural modulus retention rate. can do. It can also be adjusted by controlling the crystallinity of the bending test piece.

  The water absorption rate of the polyamide resin (A) is preferably 1% by mass or less, more preferably 0 as the water absorption rate when it is taken out after being immersed in water at 23 ° C. for 1 week and then wiped off. .6% by mass or less, more preferably 0.5% by mass or less, and particularly preferably 0.48% by mass or less. Within this range, it is easy to prevent deformation due to water absorption of the obtained composite material (C) and a molded product comprising the composite material, and it is possible to suppress foaming during molding of the composite material (C) during heating and pressurization. A molded product with few bubbles can be obtained.

The polyamide resin (A) has a terminal amino group concentration ([NH ₂ ]) of preferably 150 μeq / g or less, more preferably 5 to 120 μeq / g, and still more preferably 10 to 60 μeq / g. The terminal carboxyl group concentration ([COOH]) is preferably 250 μeq / g or less, more preferably 10 to 120 μeq / g, and still more preferably 30 to 80 μeq / g. By using the polyamide resin having such a terminal group concentration, the viscosity is easily stabilized when the polyamide resin (A) is processed into a film or fiber, and the reactivity with the carbodiimide compound described later is improved. There is a tendency.

In addition, the ratio of the terminal amino group concentration to the terminal carboxyl group concentration ([NH ₂ ] / [COOH]) is preferably 2.5 or less, more preferably 0.8 or less. When this ratio is larger than 2.5, it may be difficult to control the molecular weight when polymerizing the polyamide resin (A).

  The terminal amino group concentration can be measured by dissolving 0.5 g of polyamide resin in 30 ml of a phenol / methanol (4: 1) mixed solution with stirring at 20 to 30 ° C. and titrating with 0.01 N hydrochloric acid. As for the terminal carboxyl group concentration, 0.1 g of polyamide resin is dissolved in 30 ml of benzyl alcohol at 200 ° C., and 0.1 ml of phenol red solution is added in the range of 160 ° C. to 165 ° C. The solution was titrated with a titration solution (KOH concentration 0.01 mol / l) in which 0.132 g of KOH was dissolved in 200 ml of benzyl alcohol, and when the color change changed from yellow to red, the end point was reached. Can be calculated.

  The polyamide resin (A) used in the present invention is a molar ratio of reacted diamine units to reacted dicarboxylic acid units (number of moles of reacted diamine units / number of moles of reacted dicarboxylic acid units, hereinafter referred to as “reaction mole ratio”). Is preferably 0.97 to 1.02. By setting it as such a range, it becomes easy to control the molecular weight and molecular weight distribution of a polyamide resin (A) to arbitrary ranges. The reaction molar ratio is more preferably less than 1.0, further preferably less than 0.995, particularly less than 0.990, and the lower limit is more preferably 0.975 or more, and further preferably 0.98 or more. .

Here, the reaction molar ratio (r) is obtained by the following equation.
r = (1-cN-b (CN)) / (1-cC + a (CN))
Where
a: M1 / 2
b: M2 / 2
c: 18.015 (molecular weight of water (g / mol))
M1: Molecular weight of diamine (g / mol)
M2: Molecular weight of dicarboxylic acid (g / mol)
N: Terminal amino group concentration (equivalent / g)
C: Terminal carboxyl group concentration (equivalent / g)

  In addition, when synthesizing a polyamide resin from monomers having different molecular weights as a diamine component and a dicarboxylic acid component, it goes without saying that M1 and M2 are calculated according to the blending ratio (molar ratio) of the monomers blended as raw materials. . If the inside of the synthesis kettle is a complete closed system, the molar ratio of the charged monomers and the reaction molar ratio are the same, but the actual synthesis apparatus cannot be a complete closed system. The ratio and the reaction molar ratio do not always coincide. Since the charged monomer does not always react completely, the charged molar ratio and the reaction molar ratio are not always the same. Therefore, the reaction molar ratio means the molar ratio of the actually reacted monomer obtained from the end group concentration of the finished polyamide resin.

The reaction molar ratio of the polyamide resin (A) is adjusted by adjusting the raw dicarboxylic acid component and diamine component molar ratio, reaction time, reaction temperature, xylylenediamine dropping speed, pressure in the kettle, pressure reduction start timing, and other reaction conditions. It is possible by setting to a suitable value.
When the production method of the polyamide resin is a so-called salt method, in order to set the reaction molar ratio to 0.97 to 1.02, specifically, for example, the raw material diamine component / raw material dicarboxylic acid component ratio is within this range. Set and proceed the reaction sufficiently. In addition, in the case of a method in which a diamine is continuously added dropwise to a molten dicarboxylic acid, the amount of diamine to be refluxed during the addition of the diamine is controlled and the added diamine is added to the reaction system in addition to setting the charging ratio within this range. It can also be removed outside. Specifically, by controlling the temperature of the reflux tower to the optimum range and controlling the packing tower packing, so-called Raschig ring, Lessing ring, saddle, etc. to an appropriate shape and filling amount, the diamine is removed from the system. Just remove it. Moreover, unreacted diamine can also be removed out of the system by shortening the reaction time after diamine dropping. Furthermore, unreacted diamine can also be removed out of the reaction system as needed by controlling the dropping rate of diamine. By these methods, it is possible to control the reaction molar ratio within a predetermined range even if the charging ratio deviates from the desired range.

  The manufacturing method of a polyamide resin (A) is not specifically limited, It manufactures by a conventionally well-known method and superposition | polymerization conditions. A small amount of monoamine or monocarboxylic acid may be added as a molecular weight regulator during the polycondensation of the polyamide resin. For example, a salt composed of a diamine component containing xylylenediamine and a dicarboxylic acid such as adipic acid or sebacic acid is heated in a pressurized state in the presence of water, and polymerized in a molten state while removing added water and condensed water. It is manufactured by the method to make. It can also be produced by a method in which xylylenediamine is directly added to a molten dicarboxylic acid and polycondensed under normal pressure. In this case, in order to keep the reaction system in a uniform liquid state, diamine is continuously added to the dicarboxylic acid, while the reaction system is heated up so that the reaction temperature does not fall below the melting point of the generated oligoamide and polyamide. The polycondensation proceeds.

  Further, the polyamide resin (A) may be subjected to solid phase polymerization after being produced by a melt polymerization method. The method of solid phase polymerization is not particularly limited, and it is produced by a conventionally known method and polymerization conditions.

In the present invention, the melting point of the polyamide resin (A) is preferably 150 to 310 ° C, and more preferably 180 to 300 ° C.
Moreover, 50-100 degreeC is preferable, as for the glass transition point of a polyamide resin (A), 55-100 degreeC is more preferable, Especially preferably, it is 60-100 degreeC. Within this range, the heat resistance tends to be good.

  In addition, melting | fusing point is the temperature of the peak top of the endothermic peak at the time of temperature rising observed by DSC (differential scanning calorimetry) method. The glass transition point refers to a glass transition point measured by heating and melting a sample once to eliminate the influence on crystallinity due to thermal history and then raising the temperature again. For the measurement, for example, “DSC-60” manufactured by Shimadzu Corporation is used, the sample amount is about 5 mg, nitrogen is flowed at 30 ml / min as the atmospheric gas, and the heating rate is 10 ° C./min. Under the conditions, the melting point can be determined from the temperature at the peak top of the endothermic peak observed when the mixture is heated from room temperature to a temperature higher than the expected melting point. Next, the melted polyamide resin is rapidly cooled with dry ice, and the temperature is raised again to a temperature equal to or higher than the melting point at a rate of 10 ° C./min, whereby the glass transition point can be obtained.

  The polyamide resin (A) is also preferably a polyamide resin having at least two melting points. Polyamide resins having at least two melting points are preferred because they tend to improve heat resistance and molding processability when molding the composite material (C).

The polyamide resin having at least two melting points is a polyamide resin in which 70 mol% or more of diamine structural units are derived from xylylenediamine and 50 mol% or more of dicarboxylic acid structural units are derived from sebacic acid, The amine unit contains 50 to 100 mol% of paraxylylenediamine-derived units, 0 to 50 mol% of metaxylylenediamine-derived units, has a number average molecular weight (Mn) of 6,000 to 30,000, a melting point A polyamide resin having at least two of these can be preferably mentioned.
Under the present circumstances, two or more melting | fusing point exists in the range of 250-330 degreeC normally, Preferably it is 260-320 degreeC, More preferably, it is 270-310 degreeC, Most preferably, it is 275-305 degreeC. By having two or more melting points, preferably in such a temperature range, a polyamide resin having good heat resistance and molding processability when molding the composite material (C) is obtained. The production of such a polyamide resin can be referred to the description in paragraph Nos. 0071 to 0080 of Japanese Patent No. 4894982, the contents of which are incorporated herein.

The polyamide resin (A) used in the present invention may consist only of a polyamide resin or may contain other components such as an elastomer component. As the elastomer component, for example, known elastomers such as polyolefin elastomers, diene elastomers, polystyrene elastomers, polyamide elastomers, polyester elastomers, polyurethane elastomers, fluorine elastomers, and silicon elastomers can be used. Elastomers and polystyrene-based elastomers.
These elastomers include α, β-unsaturated carboxylic acids and their anhydrides, acrylamides and their derivatives in the presence or absence of radical initiators in order to impart compatibility with the polyamide resin (A). A modified elastomer modified with the above is also preferable.

  The content of such an elastomer component is usually 30% by mass or less, preferably 20% by mass or less, particularly 10% by mass or less in the polyamide resin (A).

Moreover, the polyamide resin (A) used by this invention may be one type, and may be two or more types.
Further, the polyamide resin (A) used in the present invention is one kind of resin such as polyester resin, polyolefin resin, polyphenylene sulfide resin, polycarbonate resin, polyphenylene ether resin, polystyrene resin and the like within a range not impairing the objects and effects of the present invention. It can also be blended. In this case, it is preferably 3% by weight or less of the total amount of the polyamide resin (A).

  Further, the polyamide resin (A) used in the present invention is a stabilizer such as an antioxidant and a heat stabilizer, a hydrolysis resistance improver, a weather resistance stabilizer, a matting agent, and the like without departing from the spirit of the present invention. Additives such as an ultraviolet absorber, a nucleating agent, a plasticizer, a dispersant, a flame retardant, an antistatic agent, an anti-coloring agent, an anti-gelling agent, a coloring agent, and a release agent can be added. For details of these, reference can be made to the description of paragraph numbers 0129 to 0155 of Japanese Patent No. 4894982, the contents of which are incorporated herein.

<Continuous fiber (B)>
As the continuous fiber (B) used in the present invention, glass fiber, carbon fiber, plant fiber (including Kenaf, bamboo fiber, etc.), alumina fiber, boron fiber, ceramic fiber, metal fiber (steel fiber, etc.), Examples thereof include aramid fiber, polyoxymethylene fiber, aromatic polyamide fiber, polyparaphenylene benzobisoxazole fiber, and ultrahigh molecular weight polyethylene fiber. Among these, carbon fibers are preferably used because they have excellent characteristics of high strength and high elastic modulus while being lightweight. As the carbon fiber, polyacrylonitrile-based carbon fiber and pitch-based carbon fiber can be preferably used.

  These continuous fibers (B) are preferably, for example, monofilaments or multifilaments arranged so as to cross one direction or alternately. Furthermore, a prepreg in which these are laminated and impregnated with a binder or the like is also preferably used.

  The average fiber diameter of the continuous fiber (B) is preferably 1 to 100 μm, more preferably 3 to 50 μm, still more preferably 4 to 20 μm, and particularly preferably 5 to 10 μm. When the average fiber diameter is within this range, the processing is easy, and the resulting molded article has excellent elasticity and strength. The average fiber diameter can be measured by observation with a scanning electron microscope (SEM) or the like. In the present invention, 50 or more fibers are randomly selected, the length is measured, and the number average average fiber diameter is calculated.

  The fineness of the continuous fiber (B) is preferably 20 to 3,000 tex, more preferably 50 to 2,000 tex. When the fineness is within this range, processing is easy, and the resulting molded article has excellent elastic modulus and strength. The fineness can be obtained by obtaining the weight of a long fiber having an arbitrary length and converting it to a weight per 1,000 m. Usually, carbon fibers having a filament number of about 500 to 30,000 can be preferably used.

The fiber length of the continuous fiber (B) present in the composite material (C) used in the present invention is an average fiber length, preferably 1 cm or more, more preferably 1.5 cm or more, and further preferably 2 cm or more. Particularly preferably, it is 3 cm or more. The upper limit of the average fiber length is not particularly limited, but is 2000 m or less, preferably 1000 m or less in terms of handling.
The method for measuring the average fiber length in the composite material (C) is not particularly limited. For example, fibers remaining after dissolving the composite material (C) in hexafluoroisopropanol (HFIP) and dissolving the polyamide resin. Can be measured by visual observation or, in some cases, observation with an optical microscope, a scanning electron microscope (SEM), or the like.

  Moreover, although there is no restriction | limiting in particular in the average fiber length of the raw material before use of the continuous fiber to be used, it is preferable that it is the range of 1-10,000m from a viewpoint of making moldability favorable, More preferably, 100- It is about 7,000 m, more preferably about 1,000 to 5,000 m.

  In the present invention, it is preferable to use a long continuous fiber as it is, superimpose it with the polyamide resin (A), heat and press it, and impregnate it to obtain the composite material (C). By using the continuous fiber (B) in such a long fiber state, the elastic modulus and strength of the obtained molded product are higher than those of a conventional chopped strand or a molding material using a continuous fiber that is broken such as a long fiber. Can be improved. In addition, the strength of the molded product can be made anisotropic, for example, the strength in a specific direction of the molded product can be improved by using long continuous fibers. However, as a matter of course, the present invention does not exclude the use of the short fibers (D) obtained by cutting the continuous fibers (B). When using a short fiber (D) together, it is preferable that the average fiber diameter of a short fiber (D) is shorter than the average fiber diameter of a continuous fiber (B).

The continuous fiber (B) has a functional group having reactivity with the polyamide resin (A) on the surface of the continuous fiber (B) in order to improve wettability and interfacial adhesion with the polyamide resin (A). preferable.
As an example having a functional group having reactivity with the polyamide resin (A), a surface treatment with a surface treatment agent or a sizing agent is preferable.

Examples of the surface treatment agent include those composed of a functional compound such as an epoxy compound, an acrylic compound, an isocyanate compound, a silane compound, and a titanate compound, such as a silane coupling agent and a titanate cup. Examples of the ring agent include silane coupling agents.
Silane coupling agents include trialkoxy or triallyloxysilane compounds such as aminopropyltriethoxysilane, phenylaminopropyltrimethoxysilane, glycidylpropyltriethoxysilane, methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, and ureido Examples include silane, sulfide silane, vinyl silane, and imidazole silane.

  As the sizing agent, an epoxy resin such as a bisphenol A type epoxy resin, an epoxy acrylate resin having an acrylic group or a methacryl group in one molecule, a bisphenol A type vinyl ester resin, a novolac type vinyl ester resin, Preferred examples include vinyl ester resins such as brominated vinyl ester resins. Further, it may be a urethane-modified resin of an epoxy resin or a vinyl ester resin.

<Production method of composite material (C)>
The composite material (C) used in the present invention can be produced by impregnating the continuous fiber (B) with the polyamide resin (A) by overlapping the polyamide resin (A) and the continuous fiber (B) and subjecting them to heat processing. The shape of the polyamide resin (A) when the continuous fiber (B) is impregnated with the polyamide resin (A) is not particularly defined, and various shapes such as film, fiber, and powder can be adopted. The shape is preferred.

  In particular, in the present invention, it is also preferable that the polyamide resin film is formed by adopting a method of applying a texture to the surface thereof. In particular, it is effective in the case where it is easy to break when trying to process thinly due to the application of minute stress or uneven stress during molding. When the film is formed with a textured surface, that is, a film having a textured surface with fine irregularities on the surface, the frictional resistance between the film surface and the take-up machine, i.e. It is considered that the film can be prevented from being broken because the stress applied to the film is reduced and can be controlled uniformly. Further, when winding, it is possible to more effectively reduce the friction between the film surfaces and to wind without wrinkles, to relieve the stress at the time of winding and to prevent the film from breaking. Furthermore, when slitting a film roll to an arbitrary width, it is possible to improve productivity because it prevents friction with the apparatus and prevents breakage.

  The wrinkles may be provided on only one side of the film or on both sides, but are preferably provided on both the front and back sides.

  The surface roughness (Ra) of the textured polyamide resin film is preferably 0.01 to 1 μm, more preferably 0.015 to 0.8 μm, still more preferably 0.1 to 0.6 μm, and particularly Is 0.2 to 0.5 μm. By setting Ra to 0.01 μm or more, the frictional force between the film and the film forming machine can be effectively reduced, and the breakage of the film during the forming process can be effectively suppressed.

  The uneven texture on the surface of the polyamide resin film is preferably such that the distance between the vertices of adjacent texture is 0.1 to 1 μm, more preferably 0.2 to 0.9 μm, still more preferably 0.5 to 0. 0.8 μm, particularly 0.6 to 0.7 μm. Within this range, the frictional force between the film and the film forming machine can be sufficiently reduced, and the stress applied to the film can be relieved, so that it is easy to prevent film breakage during molding. Moreover, since the frictional force between the films is sufficiently reduced, it becomes easy to prevent wrinkles from entering when the film is rolled up. Furthermore, it becomes easy to prevent the film from being broken when the film is post-processed.

  The surface roughness (Ra) of the film surface and the distance between the vertices of adjacent wrinkles can be measured using a scanning probe microscope. For details, reference can be made to the description of paragraph No. 0107 in Japanese Patent No. 489482, the contents of which are incorporated herein.

  The polyamide resin film thus obtained preferably has a thickness of 5 to 100 μm, more preferably 10 to 60 μm, still more preferably 10 to 55 μm, and particularly preferably 10 to 30 μm. . By setting it as such a range, the impregnation property to a continuous fiber (B) improves, and a curvature can be suppressed more effectively.

  The polyamide resin film in the impregnation step preferably has a certain amount of crystallization heat, and the crystallization heat amount is preferably 5 J / g or more. By adjusting the degree of crystallinity of the polyamide resin film or fiber in this way, the polyamide resin (A) can be easily dissolved and melted, heating and pressing energy during impregnation can be reduced, and the time required for impregnation processing can be shortened. can do. The amount of crystallization heat is more preferably 6 to 60 J / g, still more preferably 10 to 50 J / g. The crystallization heat quantity in the present invention is the heat quantity of the exothermic peak at the time of temperature rise observed by the DSC measurement method. For the measurement, for example, “DSC-60” manufactured by Shimadzu Corporation is used, the sample amount is about 5 mg, nitrogen is flowed at 30 ml / min as the atmospheric gas, and the temperature rising rate is 10 ° C./min from room temperature. The amount of crystallization heat can be determined from the exothermic peak observed when heating to a temperature above the expected melting point.

  In addition, it is preferable that the polyamide resin film or fiber in the impregnation step contains a certain amount of moisture because a plastic effect works, and the moisture content is preferably 0.01 to 0.15% by mass. . By setting it as such a range, the fluidity | liquidity at the time of impregnating a polyamide resin film or a fiber improves, it becomes easy to ooze between continuous fibers (B), and it obtains by further shape | molding a composite material (C) or it. It is possible to reduce air bubbles in the molded product to be produced, and to prevent foaming due to moisture. The moisture content is more preferably 0.04 to 0.12% by mass, and further 0.05 to 0.1% by mass. In addition, a moisture content can be calculated | required by measuring for 30 minutes by the Karl Fischer method at the temperature of melting | fusing point-5 degreeC of a polyamide resin (A).

  The form of the continuous fiber (B) when impregnating the polyamide resin (A) is not particularly defined, but as described above, the continuous fibers (B) arranged in one direction or alternately intersecting, A prepreg in which these are laminated and impregnated with a binder or the like is used. Among them, it is preferable to impregnate the continuous fibers (B) in one direction, and more preferably, the winding direction is continuous fibers ( The continuous fibers (B) are aligned so as to be in the longitudinal direction of B).

  The heating and pressurization may be performed by slitting a laminate of continuous fibers (B) on a polyamide resin film and superimposing a plurality of sheets. In the case of superimposing a plurality of sheets, for example, preferably two or more, more preferably five or more of the polyamide resin (A) film / continuous fiber (B) laminate are stacked so that both outer sides thereof are polyamide resin layers. It is desirable to combine them.

  In the heating and pressurization, the continuous fiber (B) layer is impregnated with the polyamide resin (A), and the temperature for integrating them must be equal to or higher than the temperature at which the polyamide resin (A) is softened and melted. Although it varies depending on the type and molecular weight of (A), generally a temperature range from the glass transition point of the polyamide resin (A) + 10 ° C. to the thermal decomposition temperature−20 ° C. is preferable. In the case of the polyamide resin (A) having a melting point, the melting point is preferably + 10 ° C. or higher, more preferably the melting point + 20 ° C. or higher. By heating and pressing in such a temperature range, the continuous fibers (B) of the polyamide resin (A) are better impregnated and obtained by molding the composite material (C) and further the composite material (C). The physical properties of the molded product tend to be improved. When the polyamide resin (A) has two or more melting points, the melting point here is the temperature at the peak top of the endothermic peak on the high temperature side.

  Moreover, the press pressure at the time of pressurization is preferably 0.1 MPa or more, more preferably 0.5 MPa or more, and particularly preferably 1 MPa or more. The heating and pressurization is preferably performed under reduced pressure, particularly under vacuum, and when performed under such conditions, it is preferable that bubbles do not easily remain in the obtained composite material (C).

  Further, when the composite material (C) used in the present invention is further heated and melted and processed into a molded product, the heat of crystallization of the polyamide resin (A) in the composite material (C) is 5 J / g or more. Is preferred. The amount of crystallization heat is more preferably 6 to 60 J / g, and further preferably 10 to 50 J / g. Within such a range, when the composite material (C) is wound around the core material, the composite material (C) has appropriate flexibility and good winding properties.

Moreover, it is preferable that the composite material (C) in this invention is 20 / 80-80 / 20 in the area ratio in a cross section of polyamide resin (A) / continuous fiber (B). By setting it as such a range, it exists in the tendency which the intensity | strength of a composite material (C) and a molded article obtained from this improves more. The area ratio in the cross section is more preferably 30/70 to 70/30, and further 40/60 to 60/40. In addition, a cross section here means a cross section orthogonal to the longitudinal direction of a continuous fiber (B), when the continuous fiber (B) is orientating to one direction. When the continuous fiber (B) is oriented in a plurality of directions, one direction is arbitrarily selected from the plurality of orientation directions, and the surface is perpendicular to the longitudinal direction of the oriented continuous fibers (B). Is a cross section. When the continuous fibers (B) are not oriented, any one direction of the composite material (C) is taken as a cross section. The area ratio of polyamide resin (A) / continuous fiber (B) can be determined by observing the cross section with a scanning electron microscope (SEM).
In addition, since the polyamide resin may melt and flow out when heating and pressurizing, the area ratio calculated from the mass of the polyamide resin (A) used, the mass of the continuous fibers (B), and their density, Although the area ratio of the cross-section of the composite material (C) may not be achieved, the strength of the molded article is improved by setting the area ratio in the above range.
Moreover, it is preferable that it is 10-65 mass%, and, as for the ratio of the continuous fiber (B) in a composite material (C), it is more preferable that it is 35-55 mass%.

  Furthermore, the composite material (C) used in the present invention is preferably a dense material having few voids, more preferably a void area ratio in a cross section of 5% or less, still more preferably 3% or less, and even more. Preferably it is 2% or less, particularly preferably 1% or less. In addition, the cross section here is synonymous with the cross section in the cross-sectional area ratio of the said polyamide resin (A) / continuous fiber (B). Further, the void area ratio in the cross section can be obtained by SEM observation.

  In addition, for the details of the method for producing the composite material (C) used in the present invention, the description of paragraph numbers 0111 to 0118 in Japanese Patent No. 4894982 can be referred to, and these contents are incorporated in the present specification.

<How to wind the wound product>
In the present invention, the composite material (C) is wound around a core material. The winding condition is not particularly limited, and can be appropriately adjusted according to the type of the composite material (C). For example, it can be wound under conditions of a winding tension of 40 to 60 MPa and a winding speed of 1 to 100 m / min.
The temperature at the time of winding can be performed at 15-35 degreeC, for example. Moreover, it is preferable that the relative humidity at the time of winding is 20 to 65% at 25 ° C.
The winding of the composite material (C) may be performed while swinging in the width direction. When there is thickness unevenness in the width direction of the composite material (C), when the composite material (C) is wound around the core material, even if there is a slight thickness unevenness, it is rolled up and the outer peripheral surface of the wound product The surface tends to be uneven. Even the composite material (C) having thickness unevenness in the width direction can be wound so that the thickness unevenness is substantially uniform by winding it while swinging. The surface unevenness of the outer periphery of the can be made smaller.

  The length of the composite material (C) of the wound product is preferably 200 m or more, more preferably 200 to 5000 m, and particularly preferably 500 to 2000 m. The number of turns of the composite material (C) depends on the outer diameter of the core used and the thickness of the composite material (C), but is preferably 100 turns or more, more preferably 500 to 5000 turns. Especially preferably, it is 1000 to 4000 times.

Moreover, the material of the core material of the wound product is not particularly defined, but for example, paper, vinyl chloride, polyethylene, and polypropylene are preferable. In order to prevent the composite material (C) from being charged, the core material is particularly preferably conductively processed.
The core material used in the present invention preferably has a circular cross section in the diameter direction (direction perpendicular to the width direction of the core material), but is polygonal (triangular or more, preferably hexagonal or octagonal). ) Or oval. In the case of a polygon or an ellipse, the outer diameter (D) is converted into a circle having the same area to calculate the outer diameter.

  The present invention will be described more specifically with reference to the following examples. The materials, amounts used, ratios, processing details, processing procedures, and the like shown in the following examples can be changed as appropriate without departing from the spirit of the present invention. Therefore, the scope of the present invention is not limited to the specific examples shown below.

<Synthesis example>
(Synthesis of polyamide resin (PXD10))
Into a reaction vessel having an internal volume of 50 liters equipped with a stirrer, a condenser, a cooler, a thermometer, a nitrogen introducing tube, and a strand die, 8950 g (44.25 mol) of sebacic acid and calcium hypophosphite were precisely weighed. 54 g (0.074 mol) and 6.45 g (0.079 mol) of sodium acetate were weighed and charged (the molar equivalent ratio of calcium hypophosphite and sodium acetate was 1.0). After sufficiently purging the inside of the reaction vessel with nitrogen, the pressure was increased to 0.3 MPa with nitrogen, and the temperature was raised to 160 ° C. while stirring to uniformly melt sebacic acid. Next, 6026 g (44.24 mol) of paraxylylenediamine was added dropwise over 170 minutes with stirring. During this time, the internal temperature was continuously raised to 281 ° C. In the dropping step, the pressure was controlled to 0.5 MPa, and the generated water was removed from the system through a partial condenser and a cooler. The temperature of the partial condenser was controlled in the range of 145 to 147 ° C. After completion of the dropwise addition of paraxylylenediamine, the pressure was reduced at a rate of 0.4 MPa / hour, and the pressure was reduced to normal pressure in 60 minutes. During this time, the internal temperature rose to 299 ° C. Thereafter, the pressure was reduced at a rate of 0.002 MPa / minute, and the pressure was reduced to 0.08 MPa in 20 minutes. Thereafter, the reaction was continued at 0.08 MPa until the torque of the stirring device reached a predetermined value. The reaction time at 0.08 MPa was 10 minutes. Thereafter, the inside of the system was pressurized with nitrogen, and the polymer was taken out from the strand die and pelletized to obtain about 13 kg of polyamide resin (PXD10).

(Synthesis of polyamide resin (MP10))
In a reaction vessel equipped with a stirrer, a partial condenser, a full condenser, a thermometer, a dropping funnel and a nitrogen introducing tube, and a strand die, 12,135 g (60 mol) of sebacic acid precisely weighed, sodium hypophosphite monohydrate Product (NaH ₂ PO ₂ .H ₂ O) 3.105 g (phosphorus atom concentration in the polyamide resin 50 ppm) and 1.61 g of sodium acetate were sufficiently substituted with nitrogen. Was heated to 170 ° C. with stirring. The molar ratio of sodium acetate / sodium hypophosphite monohydrate was 0.67.
To this, 8,172 g (60 mol) of a mixed diamine of 7: 3 (molar ratio) of metaxylylenediamine and paraxylylenediamine was added dropwise with stirring, and the inside of the system was continuously removed while removing the condensed water produced. The temperature was raised to. After completion of the dropwise addition of the mixed metaxylylenediamine, the melt polymerization reaction was continued for 40 minutes at an internal temperature of 260 ° C.
Thereafter, the inside of the system was pressurized with nitrogen, the polymer was taken out from the strand die, and pelletized to obtain about 24 kg of polyamide resin (MP10).

(Synthesis of polyamide resin (MXD10))
In the synthesis of MP10, a polyamide resin MXD10 was obtained in the same manner as in the synthesis example of MP10 except that metaxylylenediamine and paraxylylenediamine were used instead of metaxylylenediamine and paraxylylenediamine.

  Various physical properties of the polyamide resin were measured according to the descriptions in paragraph numbers 0157 to 0168 of Japanese Patent No. 4894982.

<Example 1>
MXD10 dried by a vacuum dryer was melt-extruded by a single screw extruder having a 30 mmφ screw, extruded through a T-die having a width of 500 mm, and a pair of stainless steel rolls provided with uneven texture on the surface, The film was pressed at a roll temperature of 70 ° C. and a roll pressure of 0.4 MPa to form a film having a texture on the film surface. The film end was slit to obtain a cast film having a thickness of 20 μm and a width of 500 mm.

Next, Toray Industries, Ltd. (Toray Industries) polyacrylonitrile-based carbon fiber (TORAYCA) T300-3000, 3000 filament, 198 tex, tensile elastic modulus: 230 GPa, average fiber diameter of 7 μm) is applied in one direction. The sheet-like material and the MXD10 film that were aligned to each other were pressurized at 1 MPa while being heated to 220 ° C. using a plurality of rolls, and continuously bonded together, and then cooled with a 40 ° C. roll. As the roll used for heat compression, the roll surface coated with a fluororesin was used. Next, while cutting the composite material to the width shown in the table below, 10 cm ² at the beginning of winding is fixed to the paper core with tape, the winding tension is 0.1 MPa, the winding speed is 1 m / min, The film was wound under conditions of 25 ° C. and 50% relative humidity.
The measurement of the contact angle with water is based on JIS R3257 using a contact angle meter DM500 manufactured by Kyowa Interface Science Co., Ltd., and a sample is cut out in a sheet form from the composite material (C), and 23 ° C. and 50% relative to the test. The humidity was adjusted for 1 hour under the condition of humidity. The contact angle θ with respect to the composite material (C) was determined by measuring the contact angle 20 seconds after water contacted the surface of the sample placed horizontally.
In addition, the measurement of the area ratio in the cross section of the polyamide resin / continuous fiber in the obtained composite material, and the void | hole area ratio in a cross section followed the description of the paragraph numbers 0184-0185 of patent 4894982.

<Other Examples and Comparative Examples>
In Example 1, the kind of resin and the production conditions of the composite material were changed as described in the following table, and others were performed in the same manner to produce a wound product.
In addition to the resins synthesized in the above synthesis examples, the following resins were used.
N6: Ube Industries grade 1022B molecular weight 22000
PP: Novatec PP (grade FB3HAT density 0.9 g / cm ³ ) manufactured by Nippon Polypro Co., Ltd.

<Evaluation of wound product>
The obtained wound product was visually observed for unevenness and wrinkles and evaluated as follows.
A: Unevenness and wrinkles are hardly recognized B: Unevenness and wrinkles are recognized at a certain rate C: Unusual because of many unevennesses and wrinkles

<Evaluation of roll>
Cut out the wound product (length: 30 cm), hold one end on the desk, and warp the other end in the air at the angle of the tip (how much the tip is tilted from the horizontal state). evaluated. The tip angle was evaluated to be, for example, 0 ° if it did not warp at all, and 90 ° if it turned straight up. In other words, it can be said that the smaller the winding height and the tip angle, the smaller the curl.

  As is clear from the above table, when the contact angle θ, width d and D / t of the composite material with respect to the water satisfy the scope of the present invention, there are almost no wrinkles and unevenness, and there is no curl was gotten.

1 Tangent 2 Vertex

Claims (8)

A wound product obtained by winding a composite material (C) containing a polyamide resin (A) and a continuous fiber (B) around a core material,
The polyamide resin (A) is a polycondensate of a diamine compound and a dicarboxylic acid compound, and 50 mol% or more of the diamine compound includes an XD-based polyamide resin that is xylylenediamine,
The xylylenediamine comprises 50-100 mol% metaxylylenediamine and 0-50 mol paraxylylenediamine;
The contact angle θ with respect to water of the composite material (C) is 65 to 82 °, the width d is more than 100 mm and 3000 mm or less,
A wound product having an outer diameter D of 152.4 mm or less and satisfying the following formula:
Formula: 200 ≦ D / t ≦ 3000
(In the above formula, D represents the outer diameter (unit: mm) of the core material, and t represents the thickness (unit: mm) of the composite material (C).) The wound product according to claim 1, further comprising an aliphatic polyamide resin as the polyamide resin (A). The number average molecular weight (Mn) of the XD-based polyamide resin is 6,000 to 30,000, and the amount of the component having a molecular weight of 1000 or less in the polyamide resin is 0.5 to 5% by mass. The wound product according to claim 1 or 2. The wound product according to any one of claims 1 to 3, wherein an outer diameter of the core material is 60 to 152.4 mm. The wound product according to any one of claims 1 to 4, wherein a thickness of the composite material (C) is 0.05 to 2 mm. The wound product according to any one of claims 1 to 5, wherein a ratio of the continuous fiber (B) in the composite material (C) is 10 to 65 mass%. The wound product according to any one of claims 1 to 6, wherein a weight per 1 m ² of the composite material (C) is 50 to 3000 g. The wound product according to any one of claims 1 to 7, wherein a width d of the composite material (C) is 120 to 2000 mm.

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