WO2015129513A1 - エポキシ樹脂組成物、樹脂硬化物、繊維強化複合材料およびプリプレグ - Google Patents
エポキシ樹脂組成物、樹脂硬化物、繊維強化複合材料およびプリプレグ Download PDFInfo
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- WO2015129513A1 WO2015129513A1 PCT/JP2015/054255 JP2015054255W WO2015129513A1 WO 2015129513 A1 WO2015129513 A1 WO 2015129513A1 JP 2015054255 W JP2015054255 W JP 2015054255W WO 2015129513 A1 WO2015129513 A1 WO 2015129513A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- 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
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
- C08G59/4014—Nitrogen containing compounds
- C08G59/4028—Isocyanates; Thioisocyanates
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- 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
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/62—Alcohols or phenols
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- 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
- C08G83/00—Macromolecular compounds not provided for in groups C08G2/00 - C08G81/00
- C08G83/007—Polyrotaxanes; Polycatenanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
- C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
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- 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
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L5/00—Compositions of polysaccharides or of their derivatives not provided for in groups C08L1/00 or C08L3/00
- C08L5/16—Cyclodextrin; Derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2400/00—Characterised by the use of unspecified polymers
- C08J2400/20—Polymers characterized by their physical structure
- C08J2400/21—Polyrotaxanes; Polycatenanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2405/00—Characterised by the use of polysaccharides or of their derivatives not provided for in groups C08J2401/00 or C08J2403/00
- C08J2405/16—Cyclodextrin; Derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
Definitions
- the present invention relates to an epoxy resin composition containing polyrotaxane, a prepreg using the same, and a fiber-reinforced composite material.
- Fiber reinforced composite materials using carbon fibers, aramid fibers, etc. as reinforcing fibers make use of their high specific strength and specific elastic modulus to make structural materials such as aircraft and automobiles, sports such as tennis rackets, golf shafts and fishing rods. It is widely used as a material for applications and general industrial applications.
- a method for producing these fiber-reinforced composite materials a method is often used in which a prepreg, which is a sheet-like intermediate material in which reinforcing fibers are impregnated with a matrix resin, is used, and a plurality of the prepregs are laminated and then cured.
- the method using a prepreg has the advantage that it is easy to obtain a high-performance fiber-reinforced composite material because the orientation, arrangement, and blending amount of the reinforcing fibers can be strictly controlled and the design flexibility of the laminated structure is high.
- a thermosetting resin composition is mainly used from the viewpoint of heat resistance and productivity, and an epoxy resin composition is preferably used from the viewpoint of adhesion to reinforcing fibers.
- Matrix resin made of epoxy resin exhibits excellent heat resistance and good mechanical properties, while the elongation and toughness of epoxy resin are lower than those of thermoplastic resin. There is a need for improvement.
- a rubber component or a thermoplastic resin having excellent toughness As a method for improving the toughness of a cured resin obtained by curing an epoxy resin composition, a rubber component or a thermoplastic resin having excellent toughness is known.
- rubber has a low elastic modulus and glass transition temperature, and lowers the elastic modulus of the cured resin. Therefore, it is difficult to balance the toughness and rigidity of the cured resin by blending the rubber component.
- Patent Documents 1 and 2 propose Methods for greatly improving the toughness of the cured resin.
- Patent Document 3 proposes a method of alloying a (meth) acrylic block copolymer with respect to an epoxy resin.
- Patent Document 5 a technique for forming a phase separation structure after the curing reaction by using an epoxy resin composition combined with an epoxy compound having a specific SP value is known.
- Patent Document 6 a technique for adding a polyrotaxane is known.
- Patent Documents 1 and 2 have problems such as deterioration of processability due to thickening and deterioration of quality such as generation of voids.
- the method of patent document 3 can give the outstanding toughness by forming a fine phase structure, the improvement of the toughness is calculated
- Patent Document 5 is a technique that can exhibit excellent toughness and rigidity of an epoxy resin cured product by forming a fine phase separation structure after curing, and a fiber-reinforced composite material as compared with the conventional technique. It can be said that this technology can greatly improve the performance of the matrix resin. On the other hand, depending on the reaction conditions, there is also a problem that the physical properties deteriorate due to the change of the phase separation structure.
- Patent Document 6 is a technology that can improve heat resistance, internal stress, and external stress relaxation properties by forming a cross-linked structure with a cyclodextrin molecule in a polyrotaxane.
- the toughness of the epoxy resin is lowered.
- An object of the present invention is to provide an epoxy resin composition from which a cured resin having excellent rigidity and toughness can be obtained, a prepreg using the epoxy resin composition, and a fiber-reinforced composite material.
- An epoxy resin composition comprising an epoxy resin (A), a polyrotaxane (B) in which a cyclic molecule is modified with a graft chain, and a curing agent (D) capable of reacting with the epoxy resin (A).
- the present invention includes a cured resin obtained by curing the above epoxy resin composition.
- the present invention includes the above-mentioned resin cured product and a fiber-reinforced composite material including reinforcing fibers.
- This invention contains the prepreg containing said epoxy resin composition and a reinforced fiber.
- the present invention includes a fiber reinforced composite material obtained by curing the prepreg.
- a cured resin having both excellent rigidity and toughness can be obtained by curing the epoxy resin composition of the present invention.
- the epoxy resin composition of the present invention comprises an epoxy resin (A), a polyrotaxane (B), and a curing agent (D) that can react with the epoxy resin (A).
- Epoxy resin (A) is a component necessary for heat resistance and mechanical property expression. Specifically, an epoxy resin having a precursor such as a compound such as phenols, amines, carboxylic acid, or intramolecular unsaturated carbon as a precursor is preferable, and these may be added in combination of not only one type but also a plurality of types.
- a precursor such as a compound such as phenols, amines, carboxylic acid, or intramolecular unsaturated carbon as a precursor is preferable, and these may be added in combination of not only one type but also a plurality of types.
- Examples of glycidyl ether type epoxy resins that use phenols as precursors include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol S type epoxy resins, epoxy resins having a biphenyl skeleton, phenol novolac type epoxy resins, and cresol novolak type epoxy resins.
- Resins Resins, resorcinol type epoxy resins, epoxy resins having a naphthalene skeleton, trisphenylmethane type epoxy resins, phenol aralkyl type epoxy resins, dicyclopentadiene type epoxy resins, diphenylfluorene type epoxy resins, and various isomers of these epoxy resins Examples include alkyl-substituted products and halogen-substituted products. Moreover, an epoxy resin obtained by modifying an epoxy resin having a phenol as a precursor with urethane or isocyanate is also included in this type.
- bisphenol A type epoxy resins include “Epicoat (registered trademark)” 825, 826, 827, 828, 834, 1001, 1002, 1003, 1004, 1004AF, 1007, 1009 (manufactured by Mitsubishi Chemical Corporation).
- "Epiclon (registered trademark)” 850 (Dainippon Ink Chemical Co., Ltd.), “Epototo (registered trademark)” YD-128 (Nippon Steel & Sumikin Chemical Co., Ltd.), DER-331, DER-332 (Dow) Chemical Co., Ltd.).
- Examples of the bisphenol S type epoxy resin include “Epiclon (registered trademark)” EXA-1515 (manufactured by Dainippon Ink and Chemicals, Inc.).
- epoxy resins having a biphenyl skeleton include “Epicoat (registered trademark)” YX4000H, YX4000, YL6616, YL6121H, YL6640 (above, manufactured by Mitsubishi Chemical Corporation), NC-3000 (manufactured by Nippon Kayaku Co., Ltd.) ) And the like.
- phenol novolac type epoxy resins include “Epicoat (registered trademark)” 152, 154 (manufactured by Mitsubishi Chemical Corporation), “Epicron (registered trademark)” N-740, N-770, N-775 ( As mentioned above, Dainippon Ink & Chemicals, Inc.) and the like can be mentioned.
- cresol novolac type epoxy resins include “Epicron (registered trademark)” N-660, N-665, N-670, N-673, N-695 (above, Dainippon Ink & Chemicals, Inc.) , EOCN-1020, EOCN-102S, EOCN-104S (manufactured by Nippon Kayaku Co., Ltd.) and the like.
- Examples of commercially available resorcinol-type epoxy resins include “Denacol (registered trademark)” EX-201 (manufactured by Nagase ChemteX Corporation).
- epoxy resins having a naphthalene skeleton include “Epiclon (registered trademark)” HP4032 (manufactured by Dainippon Ink & Chemicals, Inc.), NC-7000, NC-7300 (above, Nippon Kayaku Co., Ltd.) Etc.
- trisphenylmethane type epoxy resins examples include TMH-574 (manufactured by Sumitomo Chemical Co., Ltd.), Tactix 742 (manufactured by Huntsman Advanced Materials), and the like.
- dicyclopentadiene type epoxy resins include “Epiclon (registered trademark)” HP7200, HP7200L, HP7200H (above, Dainippon Ink & Chemicals, Inc.), Tactix558 (manufactured by Huntsman Advanced Materials), XD -1000-1L, XD-1000-2L (Nippon Kayaku Co., Ltd.).
- Examples of commercially available epoxy resins modified with urethane and isocyanate include AER4152 (produced by Asahi Kasei Epoxy Co., Ltd.) having an oxazolidone ring and ACR1348 (produced by Asahi Denka Co., Ltd.).
- dimer acid-modified bisphenol A type epoxy resins examples include “Epicoat (registered trademark)” 872 (manufactured by Mitsubishi Chemical Corporation).
- epoxy resins having amines as precursors include tetraglycidyldiaminodiphenylmethane, glycidyl compounds of xylenediamine, triglycidylaminophenol, glycidylaniline, and positional isomers of these epoxy resins, substituted groups with alkyl groups and halogens. Can be mentioned.
- tetraglycidyldiaminodiphenylmethane examples include “Sumiepoxy (registered trademark)” ELM434 (manufactured by Sumitomo Chemical), “Araldite (registered trademark)” MY720, MY721, MY9512, MY9612, MY9634, MY9663 (and above Huntsman Advanced Material). And “Epicoat (registered trademark)” 604 (manufactured by Mitsubishi Chemical Corporation).
- Examples of commercially available glycidyl compounds of xylenediamine include “TETRAD (registered trademark)”-X (manufactured by Mitsubishi Gas Chemical Company, Inc.).
- Examples of commercially available glycidyl anilines include GAN and GOT (manufactured by Nippon Kayaku Co., Ltd.).
- Examples of the epoxy resin having carboxylic acid as a precursor include glycidyl compounds of phthalic acid and various isomers of glycidyl compounds of carboxylic acids such as hexahydrophthalic acid and dimer acid.
- Examples of commercially available diglycidyl phthalate esters include “Epomic (registered trademark)” R508 (manufactured by Mitsui Chemicals), “Denacol (registered trademark)” EX-721 (manufactured by Nagase ChemteX Corporation), and the like. It is done.
- Examples of commercially available hexahydrophthalic acid diglycidyl ester include “Epomic (registered trademark)” R540 (manufactured by Mitsui Chemicals), AK-601 (manufactured by Nippon Kayaku Co., Ltd.), and the like.
- dimer acid diglycidyl ester Commercial products of dimer acid diglycidyl ester include “Epicoat (registered trademark)” 871 (manufactured by Mitsubishi Chemical Corporation) and “Epototo (registered trademark)” YD-171 (manufactured by Nippon Steel & Sumikin Chemical Co., Ltd.). Can be mentioned.
- Examples of the epoxy resin having an intramolecular unsaturated carbon as a precursor include an alicyclic epoxy resin.
- Examples of the commercially available products include “Celoxide (registered trademark)” 2021, Celoxide (registered trademark) 2080 (manufactured by Daicel Chemical Industries, Ltd.), and CY183 (manufactured by Huntsman Advanced Materials).
- the content ratio of the epoxy resin (A) is preferably 50% by mass or more, more preferably 80% by mass or more, and further preferably 90% by mass or more with respect to the entire epoxy resin composition.
- the epoxy resin composition of the present invention includes a polyrotaxane (B) in which a cyclic molecule is modified with a graft chain.
- a rotaxane is a molecule in which a cyclic molecule is generally penetrated by a dumbbell-shaped axial molecule (a linear molecule having a bulky blocking group at both ends). What is penetrated by the molecule is called polyrotaxane.
- the polyrotaxane (B) is composed of a linear molecule and at least two cyclic molecules.
- the linear molecule penetrates through the opening of the cyclic molecule, and the cyclic molecule is detached from the linear molecule at both ends of the linear molecule. It has a bulky block group to prevent separation.
- the cyclic molecule can freely move on the linear molecule, but has a structure that cannot be removed from the linear molecule by the blocking group. That is, the linear molecule and the cyclic molecule have a structure in which the form is maintained not by chemical bonding but by mechanical bonding.
- polyrotaxane Since such a polyrotaxane has high mobility of cyclic molecules, it has an effect of relieving external stress and residual stress. Further, by adding polyrotaxane to the epoxy resin composition, the same effect can be propagated to the epoxy resin.
- the linear molecule is not particularly limited as long as it is a polymer having a functional group capable of reacting with the blocking group.
- Preferred linear molecules include polyalkylene glycols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol; polybutadiene diol, polyisoprene diol, polyisobutylene diol, poly (acrylonitrile-butadiene) diol, hydrogenated polybutadiene diol, Terminal hydroxyl group polyolefins such as polyethylene diol and polypropylene diol; Polycaprolactone diol, polylactic acid, polyethylene adipate, polybutylene adipate, polyesters such as polyethylene terephthalate, polybutylene terephthalate; and terminal functional polysiloxanes such as terminal silanol type polydimethylsiloxane Terminal amino group polyethylene glycol, terminal amino group polypro Glycol, terminal amino group chain polymer such as the
- a linear molecule selected from polyethylene glycol and terminal amino group polyethylene glycol is preferably used from the viewpoint of easy synthesis of polyrotaxane.
- the linear molecule preferably has a number average molecular weight of 2,000 to 100,000, and more preferably 10,000 to 50,000.
- the blocking group is not particularly limited as long as it is a group that can be bonded to a terminal functional group of a linear molecule and is sufficiently bulky to prevent the cyclic molecule from leaving the linear molecule.
- dinitrophenyl groups, cyclodextrins, adamantane groups, trityl groups, fluoresceins, pyrenes, anthracene, etc., or a polymer main chain having a number average molecular weight of 1,000 to 1,000,000 Or a side chain etc. are mentioned.
- These blocking groups may be used alone or in combination of two or more.
- the cyclic molecule is not particularly limited as long as a linear molecule can penetrate through the opening.
- Preferred examples include cyclodextrins, crown ethers, cryptands, macrocyclic amines, calixarenes, and cyclophanes.
- Cyclodextrins are compounds in which a plurality of glucoses are cyclically linked by ⁇ -1,4-bonds.
- a cyclic molecule selected from ⁇ -, ⁇ -, and ⁇ -cyclodextrin is more preferably used.
- the cyclic molecule contained in the polyrotaxane (B) is modified with a graft chain.
- the graft chain is preferably polyester. From the viewpoint of compatibility with an epoxy resin and solubility in an organic solvent, the graft chain is more preferably an aliphatic polyester.
- Aliphatic polyesters include polylactic acid, polyglycolic acid, poly-3-hydroxybutyrate, poly-4-hydroxybutyrate, poly (3-hydroxybutyrate-co-3-hydroxyvalerate) and poly ( ⁇ -caprolactone) Preferred is a polyester selected from Among these, poly ( ⁇ -caprolactone) is particularly preferable from the viewpoint of compatibility with the epoxy resin.
- the end of the graft chain reacts easily with the epoxy resin and / or the crosslinking agent in order to easily spread the relaxation effect to the epoxy resin.
- a high group is preferred.
- the terminal of the graft chain has a group selected from an isocyanate group, a thioisocyanate group, an amine group, a glycidyl group, a carboxylic acid group, a sulfonic acid group, an alkoxysilane group, and an ammonium base.
- the epoxy resin composition of the present invention preferably contains a crosslinking agent (C) that can react with the polyrotaxane.
- a crosslinking agent (C) that can react with the polyrotaxane.
- the cross-linking agent (C) is not particularly limited, but when a polyrotaxane is added to the epoxy resin composition, it easily reacts with the epoxy resin and / or polyrotaxane in order to easily spread the relaxation effect to the epoxy resin. It is preferable to have a highly reactive group.
- Preferred examples of the crosslinking agent (C) include a polyisocyanate compound having a plurality of isocyanate groups in one molecule, a blocked polyisocyanate compound having a plurality of blocked isocyanate groups in one molecule, and a plurality of hydroxyl groups in one molecule.
- examples thereof include a polyol compound having a polycarboxylic acid compound having a plurality of carboxyl groups in one molecule.
- the compound obtained by making a polyisocyanate compound and a polyol compound react, and also the block polyisocyanate compound which protected this reaction material with the blocking agent can be used.
- a compound selected from a polyisocyanate compound and a polyol compound is preferable, and a compound selected from a block polyisocyanate compound and a polyol compound is more preferable.
- polyisocyanate compound examples include aliphatic polyisocyanate, aromatic polyisocyanate, and alicyclic polyisocyanate.
- aliphatic polyisocyanate examples include tetramethylene diisocyanate, hexamethylene diisocyanate, methylene diisocyanate, and trimethylhexamethylene diisocyanate.
- Aromatic polyisocyanates include, for example, 4,4-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, naphthalene-1,5-diisocyanate, o-xylylene diisocyanate, m-xylylene diisocyanate Examples thereof include isocyanate and 2,4-tolylene dimer.
- Examples of the alicyclic polyisocyanate include bicycloheptane triisocyanate, 4,4-methylenebis (cyclohexyl isocyanate), and isophorone diisocyanate. Two or more polyisocyanate compounds may be used in combination as required.
- the blocked polyisocyanate compound is a compound having a plurality of blocked isocyanate groups in which isocyanate groups are protected by reaction with a blocking agent and temporarily inactivated.
- the blocking agent can be dissociated when heated to a predetermined temperature.
- a block polyisocyanate compound an addition reaction product of a polyisocyanate compound and a blocking agent is used.
- the polyisocyanate compound that can react with the blocking agent include isocyanurate bodies, biuret bodies, and adduct bodies.
- this polyisocyanate compound the compound illustrated as said polyisocyanate compound is mentioned. Two or more block polyisocyanate compounds may be used in combination as required.
- the blocking agent examples include phenolic blocking agents such as phenol, cresol, xylenol, chlorophenol, and ethylphenol; lactam blocking agents such as ⁇ -caprolactam, ⁇ -valerolactam, ⁇ -butyrolactam, and ⁇ -propiolactam; Active methylene blocking agents such as ethyl acetoacetate and acetylacetone; methanol, ethanol, propanol, butanol, amyl alcohol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether, benzyl Ether, methyl glycolate, butyl glycolate, diacetone alcohol, methyl lactate, ethyl lactate Alcohol-based blocking agents such as formaldehyde oxime, acetaldoxime, acetoxime, methyl ethyl ketoxime,
- a commercially available block polyisocyanate compound may be used, for example, “Sumijoule (registered trademark)” BL-3175, BL-4165, BL-1100, BL-1265, “Desmodule (registered trademark)” TPLS -2957, TPLS-2062, TPLS-2078, TPLS-2117, Desmotherm 2170, 2265 (above, manufactured by Sumitomo Bayer Urethane Co., Ltd.), "Coronate (registered trademark)” 2512, 2513, 2520 (above, made by Nippon Polyurethane Industry) , B-830, B-815, B-846, B-870, B-874, B-882 (above, manufactured by Mitsui Takeda Chemical), TPA-B80E, 17B-60PX, E402-B80T (above, Asahi Kasei Chemicals) Etc.).
- polyol compound examples include polyester polyol, polyester amide polyol, polyether polyol, polyether ester polyol, polycarbonate polyol, and polyolefin polyol.
- a polyol compound may be used independently or may be used together 2 or more types.
- polycarboxylic acid compound examples include aromatic polycarboxylic acid and aliphatic polycarboxylic acid.
- the polycarboxylic acid compounds may be used alone or in combination of two or more.
- the epoxy resin composition may or may not contain a crosslinking agent (C).
- the content ratio of the polyrotaxane (B) is preferably 1% by mass or more and less than 50% by mass with respect to the entire epoxy resin composition.
- the content ratio is more preferably 2% by mass or more.
- the content ratio is more preferably less than 20% by mass.
- the total content ratio of the polyrotaxane (B) and the crosslinking agent (C) is 1% by mass or more and less than 50% by mass with respect to the entire epoxy resin composition. Is preferred.
- the total content ratio is more preferably 2% by mass or more.
- the total content ratio is more preferably less than 20% by mass.
- the ratio of the polyrotaxane (B) to the total amount of the polyrotaxane (B) and the crosslinking agent (C) is preferably 20% by mass or more, and more preferably 30% by mass or more.
- the ratio of the polyrotaxane (B) to the total amount of the polyrotaxane (B) and the crosslinking agent (C) is preferably less than 90% by mass, and more preferably less than 70% by mass.
- polyrotaxane (B) examples include “CELUM (registered trademark)” superpolymers SH3400P, SH2400P, SH1310P (manufactured by Advanced Soft Materials Co., Ltd.) and the like.
- C crosslinking agent
- “Celum (trademark)” elastomer S1000, M1000 (above, Advanced Soft Materials Co., Ltd. product) etc. are mentioned, for example.
- the curing agent (D) is not particularly limited as long as it can react with the epoxy resin (A), but an amine curing agent is preferably used.
- the curing agent include tetramethylguanidine, imidazole or derivatives thereof, carboxylic acid hydrazides, tertiary amines, aromatic amines, aliphatic amines, dicyandiamide or derivatives thereof.
- Examples of the imidazole derivative include 2-methylimidazole, 1-benzyl-2-methylimidazole, 2-ethyl-4-methylimidazole, and the like.
- Examples of the carboxylic acid hydrazide derivative include adipic acid hydrazide and naphthalenecarboxylic acid hydrazide.
- Examples of the tertiary amine include N, N-dimethylaniline, N, N-dimethylbenzylamine, 2,4,6-tris (dimethylaminomethyl) phenol and the like.
- aromatic amines examples include 4,4′-diaminodiphenylmethane, 4,4′-diaminodiphenylsulfone, 3,3′-diaminodiphenylsulfone, m-phenylenediamine, m-xylylenediamine, diethyltoluenediamine, and the like.
- aliphatic amine examples include diethylenetriamine, triethylenetetramine, isophoronediamine, bis (aminomethyl) norbornane, bis (4-aminocyclohexyl) methane, dimer acid ester of polyethyleneimine, and the like.
- modified amines obtained by reacting compounds having active hydrogen such as aromatic amines and aliphatic amines with compounds such as epoxy compounds, acrylonitrile, phenol and formaldehyde, thiourea, and the like are also included.
- the latent curing agent (D) a latent curing agent having excellent storage stability of the resin composition is also preferably used.
- the latent curing agent is a curing agent that exhibits activity by phase change, chemical change, or the like by a certain stimulus such as heat or light.
- Examples of the latent curing agent include an amine adduct type latent curing agent, a microcapsule type latent curing agent, dicyandiamide or a derivative thereof.
- amine adduct type latent curing agents include “Amicure (registered trademark)” PN-23, PN-H, PN-40, PN-50, PN-F, MY-24, MY-H (above, Ajinomoto Fine Techno Co., Ltd.), “ADEKA HARDNER (registered trademark)” EH-3293S, EH-3615S, EH-4070S (above, manufactured by ADEKA Corp.) and the like.
- “Novacure (registered trademark)” HX-3721, HX-3722 (above, manufactured by Asahi Kasei Chemicals Corporation) and the like can be used.
- Examples of commercially available dicyandiamide include DICY-7 and DICY-15 (manufactured by Mitsubishi Chemical Corporation). These amine curing agents may be used alone or in combination of two or more.
- dicyandiamide or a derivative thereof is particularly preferably used as the latent curing agent.
- diandiamide When dicyandiamide is used as the curing agent (D), diandiamide may be used alone or in combination with a curing accelerator or other curing agent.
- the curing accelerator to be combined include ureas, imidazoles, and Lewis acid catalysts.
- Other epoxy resin curing agents include aromatic amine curing agents, alicyclic amine curing agents, acid anhydride curing agents, and the like.
- Commercially available ureas include DCMU99 (manufactured by Hodogaya Chemical Co., Ltd.), “Omicure (registered trademark)” 24, Omicure (registered trademark) 52, Omicure (registered trademark) 94 (above CVC Specialty Specialty Chemicals, Inc.) Etc.
- Lewis acid catalysts include boron trifluoride / piperidine complex, boron trifluoride / monoethylamine complex, boron trifluoride / triethanolamine complex, boron trichloride / octylamine complex, etc. Is mentioned. From the viewpoint of storage stability and latency, it is preferable to use ureas as a curing accelerator for dicyandiamide.
- the content ratio is 0.5 to 1.2 times the amount of active groups in the epoxy resin (A) in terms of heat resistance and mechanical properties.
- the ratio is 0.7 to 1.1 times.
- the amount of active hydrogen is less than 0.5 times, the crosslink density of the cured product is lowered, so that the elastic modulus is reduced in heat resistance, and the static strength characteristics of the fiber reinforced composite material are reduced.
- the amount of active hydrogen exceeds 1.2 times, the crosslink density of the cured product is increased, the composition deformation ability is decreased, and the impact resistance may be inferior.
- the epoxy resin composition does not contain a crosslinking agent (C)
- the epoxy resin (A) and the polyrotaxane (B) are compatible before curing, and both form a phase-separated structure in the cured resin after curing. It is preferable.
- the epoxy resin composition contains a crosslinking agent (C)
- the epoxy resin (A), the polyrotaxane (B) and the crosslinking agent (C) are compatible before curing, and in the cured resin product after curing, It is preferable that they form a phase separation structure.
- Whether it is compatible or not is determined by, for example, an electron microscope, a differential scanning calorimeter, small-angle X-ray scattering, or other various methods as described in PolymerloyAlloys and Blends, Leszek A Utracki, Hanser Publishers, P.64. can do.
- phase separation structure In order to confirm the compatibility state of the epoxy resin composition before curing, it is preferable to measure using an optical microscope and a small-angle X-ray scattering apparatus.
- the phase separation structure is assumed to exist.
- no phase separation structure was observed in the optical microscope observation and no scattering derived from the phase separation structure was detected in the X-ray scattering measurement, it was determined that the phase separation structure did not exist.
- phase separation structure exists.
- a detailed measurement method will be described later.
- Whether the epoxy resin composition forms a phase-separated structure after curing was determined by heating the epoxy resin composition from 50 ° C. to 135 ° C. at 2 ° C./min and further heating at 135 ° C. for 2 hours. Later, it can confirm by observing as mentioned above.
- the epoxy resin composition of the present invention is in a compatible state before curing, and when the phase separation structure is formed by spinodal decomposition along with the curing reaction, a uniform and fine phase separation structure is formed throughout the system. Is preferable. By forming such a phase separation structure, a cured product of the epoxy resin composition having high toughness can be obtained without impairing the rigidity of the epoxy resin. In this case, the epoxy resin composition before curing starts a curing reaction by heating or the like.
- the phase is divided into two phases, a phase mainly composed of a cured epoxy resin and a phase mainly composed of a polyrotaxane or a crosslinked polyrotaxane.
- main component means that the content of the component in the phase is 80% by mass or more.
- the phase mainly composed of the cured epoxy resin includes a part of the polyrotaxane or the crosslinked polyrotaxane, and the phase mainly composed of the crosslinked polyrotaxane or the polyrotaxane includes a part of the cured epoxy resin. It will be in the state.
- the phase separation structure is roughly classified into a sea-island structure and a co-continuous structure.
- the sea-island structure refers to a structure in which island structures are scattered in the sea structure.
- the co-continuous structure refers to a structure in which two or more components to be mixed each form a continuous phase and are entangled three-dimensionally.
- the phase separation structure preferably forms a sea-island structure.
- the diameter of the island structure is preferably 0.01 ⁇ m or more, and more preferably 0.05 ⁇ m or more. If the island structure has a diameter of less than 0.01 ⁇ m, it may approach a compatible state, and the characteristics of both components may not be sufficiently exhibited. Further, the diameter of the island structure is preferably 10 ⁇ m or less, more preferably 1 ⁇ m or less, further preferably 0.5 ⁇ m or less, and particularly preferably 0.1 ⁇ m or less. When the diameter of the island structure is larger than 10 ⁇ m, the physical properties of the cured epoxy resin and the crosslinked polyrotaxane are only expressed, and it may be difficult to compensate for the disadvantages.
- the island structure is preferably a phase mainly composed of polyrotaxane or a crosslinked polyrotaxane.
- the phase of the polyrotaxane or polyrotaxane crosslinked product as a main component forms an island structure, when the resin composition breaks, the progress of cracks is easily dispersed in the phase of the polyrotaxane or polyrotaxane crosslinked product as the main component. Toughness is easy to improve.
- the sea structure is a phase mainly composed of a cured epoxy resin, so that rigidity is maintained.
- the sea structure contains a part of polyrotaxane or a crosslinked polyrotaxane, and this component has an effect of spreading the relaxation effect of polyrotaxane or polyrotaxane to the cured epoxy resin, so that the toughness is further improved.
- the structural period is preferably 0.01 ⁇ m or more, and more preferably 0.05 ⁇ m or more. If the structural period is less than 0.01 ⁇ m, the mixed state approaches and the characteristics of both components may not be sufficiently exhibited.
- the structural period is preferably 10 ⁇ m or less, more preferably 1 ⁇ m or less, further preferably 0.5 ⁇ m or less, and particularly preferably 0.1 ⁇ m or less. If the structural period is larger than 10 ⁇ m, the physical properties of the cured epoxy resin and the crosslinked polyrotaxane are only expressed, and it may be difficult to compensate for the disadvantages.
- the diameter of the island structure of the sea-island structure and the structural period of the co-continuous structure can be determined by the following method, for example, by observation with an electron microscope.
- the magnification is adjusted so that there are 50 or more and less than 100 island structures in a square electron microscope observation photograph.
- 50 island structures are randomly selected from the island structures present in the observed image, and the major axis and the minor axis are measured for each island structure.
- the average value of the major axis and the minor axis is defined as the diameter of each island structure, and the average value of the diameters of all the measured island structures is defined as the island structure diameter.
- the major axis and the minor axis of the island structure indicate the longest diameter and the shortest diameter of the island structure, respectively.
- each line intersects the boundary between two phases of 20 or more and less than 200. Adjust the observation magnification so that At such a magnification, by dividing the length of a line segment from end to end of a straight line drawn randomly in the observed image by the number of boundaries divided by 2, the structure period on that line is Get the value. The same operation was performed for 10 straight lines, and such operations were performed on 10 randomly selected electron microscopic photographs on the sample, and the number average values of the structural period values on all the straight lines were shared.
- the structure period is a continuous structure.
- the length of the line segment here is the actual length, and the actual length can be obtained based on the scale bar in the observation photograph.
- thermoplastic resin soluble in epoxy resin organic particles such as rubber particles and thermoplastic resin particles, inorganic particles, and the like can be blended within a range not impairing the object of the present invention.
- additives can be added to the epoxy resin composition as long as the object of the present invention is not impaired.
- examples of these other additives include talc, kaolin, mica, clay, bentonite, sericite, basic magnesium carbonate, aluminum hydroxide, glass flake, glass fiber, carbon fiber, asbestos fiber, rock wool, calcium carbonate, Silica sand, wollastonite, barium sulfate, glass beads, titanium oxide and other reinforcing or non-plate-like fillers; or antioxidants (phosphorous, sulfur, etc.), UV absorbers, heat stabilizers (hindered phenols) Etc.), lubricants, mold release agents, antistatic agents, antiblocking agents, colorants including dyes and pigments, flame retardants (halogen-based, phosphorus-based, etc.), flame retardant aids (antimony compounds represented by antimony trioxide) , Zirconium oxide, molybdenum oxide, etc.), foaming agent, coupling agent (glycidyl group, amino group, amino
- the fiber-reinforced composite material containing the cured product of the epoxy resin composition of the present invention and the reinforcing fiber can be obtained by combining the epoxy resin composition of the present invention with the reinforcing fiber and then curing it.
- the cured product of the epoxy resin composition of the present invention becomes a matrix resin.
- a prepreg in which an epoxy resin composition is impregnated into a reinforcing fiber base in advance because it is easy to store and excellent in handleability.
- the prepreg of the present invention includes the epoxy resin composition and reinforcing fibers.
- Examples of the method of impregnating the reinforcing fiber base material with the epoxy resin composition include a wet method and a hot melt method (dry method).
- a wet method after immersing the reinforcing fiber in a solution in which the epoxy resin composition is dissolved in a solvent such as methyl ethyl ketone or methanol, the reinforcing fiber is pulled up, and the solvent is evaporated from the reinforcing fiber using an oven or the like. This is a method of impregnating a reinforcing fiber with the composition.
- the hot melt method is a method in which a reinforcing fiber is impregnated directly with an epoxy resin composition whose viscosity is reduced by heating, or a film in which an epoxy resin composition is coated on a release paper is prepared, and then both sides of the reinforcing fiber are prepared.
- the reinforcing film is impregnated with resin by overlapping the film from one side and heating and pressing.
- the method for producing the fiber-reinforced composite material of the present invention is not particularly limited, but includes a prepreg lamination molding method, a resin transfer molding method, a resin film infusion method, a hand layup method, a sheet molding compound method, and a filament winding method. , Pultrusion method, etc.
- the reinforcing fiber is not particularly limited, and glass fiber, carbon fiber, aramid fiber, boron fiber, alumina fiber, silicon carbide fiber and the like are used. Two or more of these fibers may be mixed and used. Of these, carbon fibers that can provide a lightweight and highly rigid fiber-reinforced composite material are preferred.
- the form of the reinforcing fiber is not particularly limited.
- long fibers, tows, woven fabrics, mats, knits, braids, and non-woven fabrics using cut fibers are used.
- an array in which reinforcing fiber bundles are aligned in a single direction is most suitable.
- the fiber-reinforced composite material of the present invention is preferably used for sports applications, general industrial applications, and aerospace applications. More specifically, in sports applications, it is preferably used for golf shafts, fishing rods, tennis and badminton racket applications, stick applications such as hockey, and ski pole applications.
- structural materials for moving bodies such as automobiles, bicycles, ships and railroad vehicles, drive shafts, leaf springs, windmill blades, pressure vessels, flywheels, paper rollers, roofing materials, cables, repair and reinforcement materials, etc. Is preferably used.
- epoxy resin composition of the present invention will be described in more detail with reference to examples.
- the following resin raw materials were used.
- ⁇ Epoxy resin> ⁇ Bisphenol A type epoxy resin (YD-128, manufactured by Nippon Steel & Sumikin Chemical Co., Ltd.) ⁇ Bisphenol A type epoxy resin ("Epicoat (registered trademark)" 1004, manufactured by Mitsubishi Chemical Corporation) -Biphenyl type epoxy resin (YX-4000, manufactured by Mitsubishi Chemical Corporation).
- ⁇ Polyrotaxane> ⁇ PRX1 prepared by the following method 1.0 g of ⁇ -cyclodextrin and 4.0 g of terminal amino group polyethylene glycol having an average molecular weight of 20,000 were dissolved and stirred in distilled water at 80 ° C. to obtain an aqueous solution. The obtained aqueous solution was allowed to stand overnight in a refrigerator, and then water was removed from the resulting cloudy solution by lyophilization to obtain a white solid.
- the obtained solid was dissolved in 20 ml of dimethyl sulfoxide and dropped into 200 ml of water to cause precipitation, followed by centrifugation and removal of the supernatant. Furthermore, after washing and centrifuging with 100 ml of water and 100 ml of methanol, respectively, vacuum drying was performed to obtain a polyrotaxane having both ends blocked with adamantane groups.
- Preparation of the resin composition, preparation of the fiber reinforced composite material, and measurement of various physical properties were performed by the following methods.
- the physical properties were measured in an environment with a temperature of 23 ° C. and a relative humidity of 50% unless otherwise specified.
- the obtained epoxy resin composition was poured into a mold whose thickness was adjusted using a spacer made of “Teflon (registered trademark)” having a predetermined thickness, and was heated from 50 ° C. to 135 ° C. at 2 ° C./min. The temperature was raised and further heated at 135 ° C. for 2 hours to obtain a cured product plate.
- Teflon registered trademark
- island structures were randomly selected from the island structures present in the observed image, and the major axis and the minor axis were measured for each island structure.
- the average value of the major axis and the minor axis was taken as the diameter of each island structure, and the average value of the diameters of all the measured island structures was taken as the diameter of the island structure.
- the state where the size of the phase separation structure was less than 0.001 ⁇ m or the phase separation structure was not formed was regarded as a compatible state, and the state where a phase separation structure of 0.001 ⁇ m or more was formed was regarded as a phase separation state.
- the 90 ° bending strength of the fiber reinforced composite material was measured as an index of adhesiveness between the epoxy resin composition and the reinforcing fiber.
- the unidirectional laminate was cut out to have a thickness of 2 mm, a width of 15 mm, and a length of 60 mm.
- Instron universal testing machine manufactured by Instron
- measurement was performed at a crosshead speed of 1.0 mm / min, a span of 40 mm, an indenter diameter of 10 mm, and a fulcrum diameter of 4 mm to measure 90 ° bending strength and bending breaking elongation. .
- Examples 1 to 5 Each component was mix
- Example 6 to 14 Instead of polyrotaxane, a mixture of polyrotaxane and a crosslinking agent was used and the respective components were blended in the ratios shown in Tables 1 and 2, and a cured product of the epoxy resin composition was prepared as described in (1) above. From observation with an electron microscope, it was confirmed that all of the cured resin formed a phase-separated structure having a sea-island structure. As a result of measuring various physical properties, the obtained cured product had good bending properties, toughness, and compression properties.
- Example 15 Each component was mix
- Example 16 Instead of the polyrotaxane, a mixture of the polyrotaxane and the crosslinking agent was used and the respective components were blended in the ratios shown in Table 2 to prepare a cured product of the epoxy resin composition as described in (1) above. From observation with an electron microscope, it was confirmed that the cured resin did not form a phase separation structure but was compatible. As a result of measuring various physical properties, the bending properties and toughness of the obtained cured product were both good.
- Example 17 Each component was mix
- Example 18 Using a mixture of a polyrotaxane and a crosslinking agent, each component was blended at a ratio shown in Table 2, and a cured product of the epoxy resin composition was prepared as described in (1) above. From observation with an electron microscope, it was confirmed that the cured resin formed a phase-separated structure having a sea-island structure. As a result of measuring various physical properties, the obtained cured product had good bending properties, toughness, and compression properties. Further, a fiber-reinforced composite material unidirectional laminate was produced by the method described in (7) above. 0 ° and 90 ° bending test and was subjected to a G IC test, the value of flexural strength, flexural breaking elongation and G IC was good both.
Abstract
Description
エポキシ樹脂(A)、環状分子がグラフト鎖により修飾されたポリロタキサン(B)およびエポキシ樹脂(A)と反応し得る硬化剤(D)を含むエポキシ樹脂組成物。
本発明は、上記のエポキシ樹脂組成物を硬化させてなる樹脂硬化物を含む。
本発明は、上記の樹脂硬化物と、強化繊維を含む繊維強化複合材料を含む。
本発明は、上記のエポキシ樹脂組成物と強化繊維を含むプリプレグを含む。
本発明は、上記のプリプレグを硬化させてなる繊維強化複合材料を含む。
・ビスフェノールA型エポキシ樹脂(YD-128、新日鉄住金化学(株)製)
・ビスフェノールA型エポキシ樹脂(“エピコート(登録商標)”1004、三菱化学(株)製)
・ビフェニル型エポキシ樹脂(YX-4000、三菱化学(株)製)。
・ジシアンジアミド(DICY7、三菱化学(株)製)。
・3-(3,4-ジクロロフェニル)-1,1-ジメチルウレア(DCMU99、保土谷化学工業(株)製)。
・PRX1(下記方法で作製)
α-シクロデキストリン1.0gおよび平均分子量20,000の末端アミノ基ポリエチレングリコール4.0gを、80℃の蒸留水に溶解および撹拌し、水溶液を得た。得られた水溶液を冷蔵庫内で一晩静置した後、凍結乾燥により、得られた白濁溶液から水分を除去し、白色固体を得た。前記白色固体に、ジイソプロピルエチルアミン0.7ml、アダマンタン酢酸0.85g、1-ヒドロキシベンゾトリアゾール0.6g、ベンゾトリアゾール-1-イルオキシトリス(ジメチルアミノ)ホスホニウムヘキサフルオロホスフェート1.8gおよびジメチルホルムアミド30mlを加え、窒素封入下5℃で24時間反応させた。溶液にメタノール20mlを加え、遠心分離を行った。さらにメタノール:ジメチルホルムアミド=20ml:20mlの混合溶媒で2回、メタノール60mlで2回の洗浄および遠心分離操作を行った後、真空乾燥した。得られた固体をジメチルスルホキシド20mlに溶解し、水200mlに滴下して沈殿を生じせしめ、遠心分離を行い、上澄みを除去した。さらに、水100ml、メタノール100mlでそれぞれ洗浄および遠心分離後、真空乾燥し、両末端をアダマンタン基で封鎖したポリロタキサンを得た。
・“セルム(登録商標)”スーパーポリマーSH3400P(アドバンスト・ソフトマテリアル(株)製)
・“セルム(登録商標)”スーパーポリマーSH2400P(アドバンスト・ソフトマテリアル(株)製)
・“セルム(登録商標)”スーパーポリマーSH1310P(アドバンスト・ソフトマテリアル(株)製)
(これらの“セルム(登録商標)”スーパーポリマーは、ポリロタキサンであり、環状分子はα-シクロデキストリン、直鎖分子はポリエチレングリコール、ブロック基はアダマンタン基である。さらに、環状分子はポリ(ε-カプロラクトン)からなるグラフト鎖により修飾されている)。
・“セルム(登録商標)”エラストマーS-1000(アドバンスト・ソフトマテリアル(株)製)
・“セルム(登録商標)”エラストマーM-1000(アドバンスト・ソフトマテリアル(株)製)
(これらの“セルム(登録商標)”エラストマーは、ポリロタキサンおよび架橋剤の混合物であり、ポリロタキサンの環状分子はα-シクロデキストリン、直鎖分子はポリエチレングリコール、ブロック基はアダマンタン基である。さらに、環状分子はポリ(ε-カプロラクトン)からなるグラフト鎖により修飾されている。また、架橋剤はポリイソシアネート化合物およびポリオール化合物を含む)。
・“ナノストレングス(登録商標)”M22N(アクリル系ブロック共重合体、アルケマ(株)製)。
(1)エポキシ樹脂組成物およびその硬化物の作製
各種エポキシ樹脂を良く撹拌しながら混合し、均一な状態とした後に、ポリロタキサンを加えた。さらに良く撹拌しながら混合し、均一な状態とし、硬化剤として、硬化剤中の活性水素量がエポキシ樹脂中のエポキシ基量の0.8倍となるよう、ジシアンジアミドを加え、さらに硬化促進剤として3-(3,4-ジクロロフェニル)-1,1-ジメチルウレアを加えて、それぞれの粉末が十分に均一になるまで撹拌し、エポキシ樹脂組成物を作製した。
エポキシ樹脂組成物を作製する際、エポキシ樹脂およびポリロタキサンを撹拌することにより得られた混合物の一部を採取し、観察倍率50倍の光学顕微鏡および小角X線散乱装置(SAXSess MC2)を用いて測定し、目視およびX線散乱それぞれの手法により相溶状態を確認した。光学顕微鏡観察により相分離構造が観察されるか、X線散乱測定において相分離構造由来の散乱が検出された場合、相分離構造が存在するとした。光学顕微鏡観察において相分離構造が観察されず、かつ、X線散乱測定において相分離構造由来の散乱が検出されなかった場合、相分離構造が存在しないとした。
作製した樹脂硬化物を、モルホロジーに十分なコントラストが付くよう、OsO4を用いて染色後、薄切片化し、H-7100透過型電子顕微鏡(日立(株)製)を用いて加速電圧100kVにて、観察倍率50000倍において観察した。さらに、相分離構造が観察された場合は、以下の手順で透過電子像を取得し、島構造の直径を求めた。正方形の電子顕微鏡観察写真に島構造が50個以上100個未満存在するよう、適切な倍率に調整した。かかる倍率において、観察像に存在する島構造から無作為に50個の島構造を選択し、それぞれの島構造について長径と短径を測定した。長径と短径の平均値を各島構造の直径とし、測定した全ての島構造の直径の平均値を島構造の直径とした。相分離構造のサイズが0.001μm未満であるか、相分離構造を形成していない状態を相溶状態とし、0.001μm以上の相分離構造を形成している状態を相分離状態とした。
エポキシ樹脂組成物を、2mm厚の“テフロン(登録商標)”製スペーサーを用いて厚み2mmになるように設定したモールド中で硬化させ、厚さ2mmの樹脂硬化物を得た。これを幅10mm、長さ60mmの試験片に切り出し、インストロン万能試験機を用い、最大容量5kNのロードセルを使用し、スパン間長さを32mm、クロスヘッドスピードを100mm/分とし、JIS K7171(2008)に準拠して3点曲げ測定を実施し、曲げ弾性率および曲げ撓み量を得た。サンプル数n=5とし、その平均値で比較した。
エポキシ樹脂組成物を、6mm厚の“テフロン(登録商標)”製スペーサーを用いて厚み6mmになるように設定したモールド中で硬化させ、厚さ6mmの樹脂硬化物を得た。この樹脂硬化物を12.7×150mmの試験片に切り出した。インストロン万能試験機(インストロン社製)を用い、ASTM D5045(1999)に従って試験片の加工および測定をおこなった。サンプル数n=5とし、その平均値で比較した。なお、試験片への初期の予亀裂の導入は、液体窒素温度まで冷やした剃刀の刃を試験片にあてハンマーで剃刀に衝撃を加えることで行った。ここでいう、樹脂靱性値とは、変形モード1(開口型)の臨界応力強度のことを指している。
エポキシ樹脂組成物を、6mm厚の“テフロン(登録商標)”製スペーサーを用いて厚み6mmになるように設定したモールド中で硬化させ、厚さ6mmの樹脂硬化物を得た。ついで、この樹脂硬化物の板から一辺の長さが6mmの立方体の試験片を切り出し、試験速度5mm/分で、他の条件はJIS K7181(2011)に準じた条件により圧縮弾性率、圧縮降伏応力、圧縮破壊応力、および圧縮破壊時呼び歪みを測定した。サンプル数はn=5とし、平均値をそれぞれ圧縮弾性率、圧縮降伏応力、圧縮破壊応力、および圧縮破壊時呼び歪みとした。
(7)一方向プリプレグの作製
(1)で作製した硬化前のエポキシ樹脂組成物を、リバースロールコーターを使用して離型紙上に塗布し、樹脂フィルムを作製した。次に、シート状に一方向に整列させた炭素繊維“トレカ(登録商標)”T800H(東レ(株)製)の両面に、前記樹脂フィルム2枚を重ね、加熱加圧して樹脂組成物を炭素繊維に含浸させ、単位面積辺りの炭素繊維重量125g/m2、繊維重量含有率75%の一方向プリプレグを作製した。
上記(7)で作製した一方向プリプレグを、繊維方向を揃えて20ply積層した。積層したプリプレグをナイロンフィルムで隙間のないように覆った。これをオートクレーブ中で135℃、内圧588kPaで2時間加熱加圧して硬化し、一方向積層板を作製した。
繊維強化複合材料の曲げ強度の指標として、一方向積層板の0°曲げ強度を測定した。一方向積層板を、厚み2mm、幅15mm、長さ100mmとなるように切り出した。インストロン万能試験機(インストロン社製)を用い、クロスヘッド速度5.0mm/分、スパン80mm、圧子径10mm、支点径4mmで測定を行ない、0°曲げ強度および曲げ破断伸度を測定した。また、作製したプリプレグの目付に基づいて、実Vf(体積炭素繊維含有率)を求めた後、得られた曲げ強度および曲げ破断伸度をVf60%に換算した。サンプル数n=5とし、その平均値を曲げ強度および曲げ破断伸度とした。
エポキシ樹脂組成物と強化繊維の接着性の指標として、繊維強化複合材料の90°曲げ強度を測定した。一方向積層板を、厚み2mm、幅15mm、長さ60mmとなるように切り出した。インストロン万能試験機(インストロン社製)を用い、クロスヘッド速度1.0mm/分、スパン40mm、圧子径10mm、支点径4mmで測定をおこない、90°曲げ強度および曲げ破断伸度を測定した。また、作製したプリプレグの目付に基づいて、実Vfを求めた後、得られた曲げ強度および曲げ破断伸度をVf60%に換算した。サンプル数n=5とし、その平均値を曲げ強度および曲げ破断伸度とした。
・モードI層間靭性(GIC)試験用複合材料製平板の作製とGIC測定
JIS K7086(1993)に従い、次の(a)~(f)の操作によりGIC試験用複合材料製平板を作製した。
表1に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、いずれも海島構造の相分離構造を形成していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性はいずれも良好であった。
ポリロタキサンの代わりに、ポリロタキサンおよび架橋剤の混合物を用い表1および2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、いずれも海島構造の相分離構造を形成していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性はいずれも良好であった。
表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、相分離構造を形成しておらず、相溶していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性および靭性はいずれも良好であった。
ポリロタキサンの代わりに、ポリロタキサンおよび架橋剤の混合物を用い、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、相分離構造を形成しておらず、相溶していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性および靭性はいずれも良好であった。
表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、海島構造の相分離構造を形成していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性はいずれも良好であった。さらに前記(7)に記載の方法により、繊維強化複合材料の一方向積層板を作製した。0°および90°曲げ試験並びにGIC試験を行ったところ、曲げ強度、曲げ破断伸度およびGICの値はいずれも良好であった。
ポリロタキサンおよび架橋剤の混合物を用い、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、海島構造の相分離構造を形成していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性はいずれも良好であった。さらに前記(7)に記載の方法により、繊維強化複合材料の一方向積層板を作製した。0°および90°曲げ試験並びにGIC試験を行ったところ、曲げ強度、曲げ破断伸度およびGICの値はいずれも良好であった。
ポリロタキサンを配合しないで、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、相分離構造を形成しておらず、相溶していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性は実施例1~4、6~11と比較し劣る結果となった。
ポリロタキサンを配合しないで、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、相分離構造を形成しておらず、相溶していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性および靭性は、実施例15および16と比較し劣る結果となった。
ポリロタキサンとして、グラフト鎖により修飾されていないポリロタキサンを用い、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、海島構造の相分離構造を形成していることを確認した。ポリロタキサンのシクロデキストリンがグラフト鎖により修飾されていないため、島構造の直径が10μmを超える相分離構造を形成していた。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性のバランスは実施例5、12~14、17および18と比較し劣る結果となった。
ポリロタキサンを配合しないで、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、相分離構造を形成しておらず、相溶していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性のバランスは、実施例5、12~14、17および18と比較し劣る結果となった。さらに前記(7)に記載の方法により、繊維強化複合材料の一方向積層板を作製した。0°および90°曲げ試験並びにGIC試験を行った結果、実施例17および18と比較し、曲げ強度、曲げ破断伸度およびGICの値のいずれも劣る結果となった。
ポリロタキサンの代わりに、ブロックコポリマーを配合し、表2に記載の比率で各成分を配合し、前記(1)に記載の通りエポキシ樹脂組成物の硬化物を作製した。電子顕微鏡観察から、樹脂硬化物は、海島構造の相分離構造を形成していることを確認した。各種物性測定を行った結果、得られた硬化物の曲げ特性、靭性および圧縮特性のバランスは実施例5、12~14および17~18と比較し劣る結果となった。
Claims (11)
- エポキシ樹脂(A)、環状分子がグラフト鎖により修飾されたポリロタキサン(B)およびエポキシ樹脂(A)と反応し得る硬化剤(D)を含むエポキシ樹脂組成物。
- さらにポリロタキサンと反応し得る架橋剤(C)を含む請求項1に記載のエポキシ樹脂組成物。
- ポリロタキサン(B)および架橋剤(C)の合計の含有比率が、エポキシ樹脂組成物全体に対して1質量%以上50質量%未満である請求項2に記載のエポキシ樹脂組成物。
- 架橋剤(C)がポリイソシアネート化合物およびポリオール化合物から選ばれた化合物である請求項2または3に記載のエポキシ樹脂組成物。
- エポキシ樹脂(A)およびポリロタキサン(B)が相溶しており、かつ、エポキシ樹脂組成物を50℃から135℃まで2℃/分で昇温し、さらに135℃で2時間加熱することにより得られる樹脂硬化物が相分離構造を形成する請求項1に記載のエポキシ樹脂組成物。
- エポキシ樹脂(A)、ポリロタキサン(B)および架橋剤(C)が相溶しており、かつ、エポキシ樹脂組成物を50℃から135℃まで2℃/分で昇温し、さらに135℃で2時間加熱することにより得られる樹脂硬化物が相分離構造を形成する請求項2~4のいずれかに記載のエポキシ樹脂組成物。
- 前記相分離構造が海島構造を形成し、島構造の直径が0.01~10μmである請求項5または6に記載のエポキシ樹脂組成物。
- 請求項1~7のいずれかに記載のエポキシ樹脂組成物を硬化させてなる樹脂硬化物。
- 請求項8に記載の樹脂硬化物と、強化繊維を含む繊維強化複合材料。
- 請求項1~7のいずれかに記載のエポキシ樹脂組成物と強化繊維を含むプリプレグ。
- 請求項10に記載のプリプレグを硬化させてなる繊維強化複合材料。
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US11345784B2 (en) | 2018-11-09 | 2022-05-31 | Panasonic Intellectual Property Management Co., Ltd. | Resin composition, and resin film, metal foil with resin, metal clad laminate, wiring board, and circuit mount component using same |
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Also Published As
Publication number | Publication date |
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JP5804222B1 (ja) | 2015-11-04 |
TW201546164A (zh) | 2015-12-16 |
TWI643899B (zh) | 2018-12-11 |
EP3112420A1 (en) | 2017-01-04 |
CN106029777B (zh) | 2017-11-28 |
EP3112420B1 (en) | 2018-10-31 |
EP3112420A4 (en) | 2017-08-30 |
JPWO2015129513A1 (ja) | 2017-03-30 |
KR20160127023A (ko) | 2016-11-02 |
US20160340485A1 (en) | 2016-11-24 |
CN106029777A (zh) | 2016-10-12 |
US10829603B2 (en) | 2020-11-10 |
KR102235448B1 (ko) | 2021-04-02 |
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