JP6176802B2 - 複合構造体のための導電性表面材料 - Google Patents
複合構造体のための導電性表面材料 Download PDFInfo
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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- H02G13/00—Installations of lightning conductors; Fastening thereof to supporting structure
- H02G13/80—Discharge by conduction or dissipation, e.g. rods, arresters, spark gaps
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- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- H05K9/0084—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising a single continuous metallic layer on an electrically insulating supporting structure, e.g. metal foil, film, plating coating, electro-deposition, vapour-deposition
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- H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
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Description
よい。
脂成分は、高いTg、高い架橋密度を生成するように配合されている。高Tg、高架橋密度の組合せが、樹脂フィルムに、アルコール系塗料剥離溶液に高い耐性を持たせる。これらの特性を達成するために、樹脂フィルム組成物は、特定の多機能樹脂、マトリックス樹脂を強靭にする高分子強化成分、潜在性アミン系硬化剤、流体バリア成分としてセラミック小球体、およびレオロジー修正成分として粒子状の無機充填剤である。多機能樹脂およびセラミック小球体は、全組成物の35重量%以上、好ましくは45重量%以上から構成される。
Chemicalsによって供給されるEPONEX脂環式エポキシ樹脂、例えば、EPONEX Resin 1510を挙げてもよい。
子の適切な源である。Kane Ace MX120、MX125、またはMX156は、DER331樹脂に分散された25〜37重量%の同コアシェルゴム粒子を含有し、コアシェルゴム粒子の適切な源でもある。MX257、MX215、MX217およびMX451等のコアシェルゴム粒子のその他の適切な源も使用してよい。コアシェルゴム粒子の別の市販されている源は、ダウ・ケミカル社のParaloid(商標)EXL−2691(平均粒径が約200nmのメタクリラート−ブタジエン−スチレンCSR粒子)である。
系材料を、導電性添加剤として使用してもよい。ナノファイバーの粒径は70〜200ナノメートルの範囲にあり、長さは約50〜200ミクロンである。ナノチューブの外径は約10ナノメートルであり、長さは約10,000ナノメートルであり、アスペクト比(L/D)は約1000である。さらに、導電性添加剤はカーボンブラック粒子(DeGussaのPrintex XE2等)を含んでもよい。
%〜35%のセラミック小球体、1%〜5%の潜在性アミン系硬化剤、0.5%〜3%の硬化促進剤、1%〜3%の無機充填剤、および任意で、銀フレークまたは銀−銅フレーク、または上で説明した炭素系ナノサイズの材料等の45%〜70%の導電性添加剤。
〜7)、導電性添加剤(銀フレークまたはAg−Cuフレーク)も混合容器に添加した。セラミック小球体、ヒュームドシリカ、および(いくつかの配合物において)UV安定剤をさらに混合容器に添加した。上記混合物の粘度を制御するために、必要に応じて、MEK溶剤を約80重量%の固形物に添加し、組成物の成分を、約1000〜3000rpmで約50〜70分間混合した。組成物の温度は約160°F未満に維持した。混合物が混合シャフトを登るのを抑制するために、追加のMEKを必要に応じて添加した。
した。
”×6”試料サイズ、0.15mmの厚みの形態で)も測定した。塗装試験パネルを−55℃〜71℃、最大2000Xサイクルの熱サイクルにかけた。熱サイクル後の各試験パネルの表面を、400X、800X、1200X、1600Xおよび2000Xの熱サイクルに露光した後の微小亀裂の発生について顕微鏡下で調べた。亀裂密度(試験パネルのサイズ領域に示される表面塗装亀裂数)を使用して、表面化複合試験パネルの微小亀裂耐性を測定する。亀裂の最大長は0.1インチ未満のはずである。2000X熱サイクル後の微小亀裂の試験結果を表5に示す。
Claims (22)
- 落雷保護または電磁波遮蔽を提供することができる導電性表面材料であって、表面材料は以下を含む多層構造であって、
(a)2つの対向する表面および3ミル未満の厚さ、および10mΩ未満の抵抗率を有する導電層、
(b)導電層の少なくとも1つの表面に形成される樹脂フィルムであって、当該樹脂フィルムは以下を含む硬化性組成物から形成され、
複数のエポキシ官能性を有するエポキシノボラック樹脂、
エポキシノボラック樹脂ではない、三官能または四官能エポキシ樹脂、
セラミック小球体、
潜在性アミン系硬化剤、
粒子状無機充填剤、および
以下から成る群から選択される少なくとも一つの強化剤、以下、(i)エポキシ樹脂、ビスフェノール、およびエラストマーの反応によって形成される反応前付加物、(ii)ポリエーテルスルホン(PES)、およびポリエーテルエーテルスルホン(PEES)の共重合体、(iii)コアシェルゴム(CSR)粒子、およびそれらの組合せ、並びに
硬化時に、樹脂フィルムは180℃以上のガラス転移温度(Tg)、およびASTM
D−3363に準拠して測定したときに、7H以上の表面鉛筆硬度を有する、導電性表面材料。 - 樹脂フィルムが0.01〜0.03psfの範囲のフィルム重量を有する請求項1に記載の導電性表面材料。
- 導電層が3μm〜38μmの範囲の厚さを有する請求項1または2に記載の導電性表面材料。
- 導電層は、3μm〜5μmの範囲の厚さを有する金属箔である請求項1〜3のいずれか1項に記載の導電性表面材料。
- 金属箔は、銅、アルミニウム、青銅、またはそれらの合金から選択される金属を含む、請求項1〜4のいずれか1項に記載の導電性表面材料。
- 樹脂フィルムは、20℃〜25℃の範囲の周囲温度で7日間ベンジルアルコール系塗料剥離液に接触した後に、0.5%未満の液体吸収およびせいぜい2Hの鉛筆グレードの硬度の低下を示す、請求項1〜5のいずれか1項に記載の導電性表面材料。
- 樹脂フィルムは、樹脂フィルム全体に分配される導電性粒子またはフレークをさらに含む、請求項1〜6のいずれか1項に記載の導電性表面材料。
- 導電性粒子またはフレークは、銀、金、アルミニウム、銅、青銅、炭素、およびそれらの組合せから選択される導電性材料から形成される、請求項7に記載の導電性表面材料。
- 多層構造の表面抵抗率は5mΩ未満である請求項7に記載の導電性表面材料。
- 金属層が2つの樹脂フィルムの間に挟まれるように、2つの樹脂フィルムが金属層の対向表面に形成される、請求項1〜9のいずれか1項に記載の導電性表面材料。
- 2つの樹脂フィルムの組成が異なる請求項10に記載の導電性表面材料。
- 2つの樹脂フィルムの組成が同じである請求項10に記載の導電性表面材料。
- −55℃〜71℃で2000X熱サイクル試験に供した後に、樹脂フィルムが0.3クラック/平方インチ未満の微小亀裂密度を示す、請求項1〜12のいずれか1項に記載の導電性表面材料。
- 熱硬化性組成物中の少なくとも1つの強化剤は、テトラブロモビスフェノールAのジグリシジルエーテル、ビスフェノールA、およびアミン末端ブタジエンアクリロニトリル(ATBN)、またはカルボキシル末端ブタジエンアクリロニトリル(CTBN)エラストマーの反応によって形成される反応前付加物を含む、請求項1〜14のいずれか1項に記載の導電性表面材料。
- 硬化性組成物は、強化剤として反応前付加物およびPES−PEES共重合体を含む、請求項1〜15のいずれか1項に記載の導電性表面材料。
- セラミック小球体は、シリカ−アルミナセラミック材料から成る中空微小球体であり、1〜50ミクロンの範囲の粒径を有する、請求項1〜16のいずれか1項に記載の導電性表面材料。
- エポキシ樹脂およびセラミック小球体は、熱硬化性組成物の総重量の35重量%以上を占める、請求項1〜17のいずれか1項に記載の導電性表面材料。
- 硬化性組成物は、硬化促進剤としてビス尿素をさらに含む、請求項1〜18のいずれか1項に記載の導電性表面材料。
- 請求項1〜19のいずれか1項に記載の導電性表面材料に由来する自動テープ敷設(ATL)または自動繊維配置(AFP)に適した導電性プリプレグテープであって、6インチ〜12インチ(152mm〜305mm)または0.125インチ〜1.5インチ(3.17mm〜38.1mm)の範囲の幅を有する導電性プリプレグテープ。
- 以下を含む複合構造体の製造方法であって、
複合構造体を形成するために、成形表面に直接プリプレグテープを分配し、圧縮する手段を備えた自動化システムを用いて、自動テープ敷設(ATL)または自動繊維配置(AFP)工程でプリプレグテープを積層し、
プリプレグテープが最終複合構造体の最外層に位置するように、ATLまたはAFPプロセスに、請求項20に記載の導電性プリプレグテープを組み込むことを含む、複合構造体の製造方法。 - 以下を含む複合構造体であって、
マトリックス樹脂を含浸させた強化繊維を含む複合基材、および
金属層が樹脂フィルムと複合基材との間に配置されるように、複合基材の表面に形成された請求項1〜19のいずれか1項に記載の導電性表面材料を含む、複合構造体。
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