WO2017061502A1 - 繊維強化樹脂及びその製造方法並びに成形品 - Google Patents
繊維強化樹脂及びその製造方法並びに成形品 Download PDFInfo
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- WO2017061502A1 WO2017061502A1 PCT/JP2016/079689 JP2016079689W WO2017061502A1 WO 2017061502 A1 WO2017061502 A1 WO 2017061502A1 JP 2016079689 W JP2016079689 W JP 2016079689W WO 2017061502 A1 WO2017061502 A1 WO 2017061502A1
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- 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
- C08G59/14—Polycondensates modified by chemical after-treatment
- C08G59/1433—Polycondensates modified by chemical after-treatment with organic low-molecular-weight compounds
- C08G59/1438—Polycondensates modified by chemical after-treatment with organic low-molecular-weight compounds containing oxygen
- C08G59/1455—Monocarboxylic acids, anhydrides, halides, or low-molecular-weight esters thereof
- C08G59/1461—Unsaturated monoacids
- C08G59/1472—Fatty acids
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- C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
- C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
- C08G69/08—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from amino-carboxylic acids
- C08G69/14—Lactams
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- C08G69/00—Macromolecular compounds obtained by reactions forming a carboxylic amide link in the main chain of the macromolecule
- C08G69/02—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids
- C08G69/26—Polyamides derived from amino-carboxylic acids or from polyamines and polycarboxylic acids derived from polyamines and polycarboxylic acids
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- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
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- 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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- 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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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
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- C08K7/00—Use of ingredients characterised by shape
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- C08K7/04—Fibres or whiskers inorganic
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- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
- C08L71/02—Polyalkylene oxides
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- C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2300/00—Characterised by the use of unspecified polymers
- C08J2300/24—Thermosetting resins
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- C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C08J2377/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
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- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/06—Elements
Definitions
- the present invention relates to a resin composition containing reinforcing fibers, a method for producing the same, and a molded product (or fiber-reinforced composite material) formed from the resin composition.
- Carbon fiber reinforced composite material (CFRP) containing carbon fiber (carbon fiber) and matrix resin is excellent in strength, rigidity, etc., and used in various applications (for example, primary structural members of aircraft, automotive members, windmill blades, various electronic devices) Etc.).
- Particularly important physical properties in such applications include mainly physical strength, such as impact strength, elastic modulus, bending strength, interlayer toughness, and the like.
- CFRP containing matrix resin for example, epoxy resin component
- carbon fiber for example, various studies have recently been made on reinforcement of CFRP with polyamide fine particles.
- Patent Document 1 Japanese Patent Laid-Open No. 2014-145003
- Patent Document 1 includes a reinforcing fiber, an epoxy resin, and polymer particles having two types of average particle diameters, and the average particle diameter of the polymer particles is 10 to 30 ⁇ m.
- a prepreg (intermediate molding material) in which the glass transition temperature of polymer particles having a large particle size is 80 to 180 ° C. is disclosed.
- polyamide fine particles are prepared by a chemical pulverization method in which a polyamide is dissolved in a solvent, and then a poor solvent is dropped and precipitated.
- Patent Document 2 discloses a composition comprising a reinforcing fiber, a thermosetting resin, a crystalline polyamide and an amorphous polyamide, and has a specific storage elastic modulus and a glass transition of 80 to 180 ° C.
- a prepreg comprising particles having a temperature is disclosed.
- polyamide fine particles are prepared by a chemical pulverization method in which a crystalline polyamide and an amorphous polyamide are dissolved in a solvent and then deposited by dropping a poor solvent.
- Patent Document 3 discloses a composition containing reinforcing fibers, spherical polyamide resin particles having an average particle diameter of 12 to 70 ⁇ m, and a matrix resin as a composition for a fiber-reinforced composite material that can be used as a prepreg. Is disclosed.
- polyamide resin particles are prepared by a forced emulsification method in which polyamide is melt-kneaded using a material incompatible with polyamide.
- JP 2014-145003 A (Claim 1, Example) Japanese Patent No. 5655976 (Claims, Examples) WO2015 / 033998 pamphlet (claims, examples)
- an object of the present invention is to provide a resin composition capable of improving the reinforcing effect of reinforcing fibers (particularly carbon fibers), a method for producing the same, and a molded product formed from the resin composition.
- Another object of the present invention is to provide a resin composition that is excellent in handleability and can easily improve the interlayer toughness of CFRP, a method for producing the same, and a molded product formed from the resin composition.
- Patent Documents 1 and 2 also examine the temperature dependence of the glass transition temperature and storage elastic modulus G ′ of a polyamide resin, and these characteristics are the characteristics of the polyamide resin itself that constitutes the fine particles.
- CFRP CFRP
- thermoplastic resin may be added with fine particles for reinforcement.
- the reason for the addition is that the extension energy of cracks generated in the matrix due to impact or the like is absorbed by the energy that breaks the interface between the fine particles and the matrix or the energy that deforms or breaks the fine particles. Accordingly, in general, it is preferable that the fine particles to be added and the matrix resin have sufficient affinity, and conversely, it is preferable that there is no gap. Further, the fracture mode of the fine particles themselves is preferably not ductile but ductile. All of these tendencies are closely related to the higher-order structure (crystallinity, etc.) of the fine particles themselves, but no such study has been conducted at present.
- DSC differential scanning calorimetry
- a freeze pulverization method for example, a method in which a resin is cooled and embrittled with liquid nitrogen or the like and then pulverized or pulverized by physical force to form a powder.
- the resin constituting the fine particles it is natural that the amorphous resin has a lower crystallinity when it is made fine particles than the semicrystalline resin, but it is amorphous and 150 to 190 ° C.
- a resin that can maintain its shape under the curing conditions of epoxy resin has a very high glass transition temperature, and becomes brittle in the temperature range from room temperature to 100 ° C., so an amorphous resin cannot provide a sufficient reinforcing effect. . Therefore, the present inventors have found that the resin capable of improving the reinforcing effect is a semi-crystalline resin and needs to be a resin having a low crystallinity as fine particles.
- the resin composition of the present invention is a resin composition containing reinforcing fibers (A), resin particles (B) and matrix resin (C), wherein the reinforcing fibers (A) contain carbon fibers, and the resin
- the particles (B) contain a semicrystalline thermoplastic resin and are heated at a rate of 10 ° C./min by differential scanning calorimetry (DSC), the glass transition temperature and melting point of the semicrystalline thermoplastic resin It has an exothermic peak in the temperature range between and an average particle size of 3 to 40 ⁇ m.
- the semi-crystalline thermoplastic resin is a polyamide resin having a melting point of 150 ° C. or higher (in particular, a polyamide resin having an alicyclic structure and a glass transition temperature of 100 ° C.
- the semi-crystalline thermoplastic resin may be a polyamide resin (particularly an aliphatic polyamide resin) having a ⁇ -type crystal structure or a crystallinity of 50% or less.
- the resin particles (B) may further contain an impact modifier.
- the matrix resin (C) may be a thermosetting resin.
- the resin particles (B) may be spherical and may have an average particle size of 15 to 25 ⁇ m.
- a semi-crystalline thermoplastic resin and an aqueous medium incompatible with the resin are melt-kneaded, and then the aqueous medium is removed with a hydrophilic solvent from the obtained melt-kneaded product to obtain resin particles (B).
- the resin composition manufacturing method including the resin particle manufacturing step of obtaining the resin particles and the impregnation step of impregnating the reinforcing fiber (A) with the obtained resin particles (B) and the matrix resin (C) is also included.
- the glass transition temperature of the semicrystalline thermoplastic resin may be dried at a temperature of (Tg + 40) ° C. or lower, where Tg is the glass transition temperature.
- the present invention also includes a molded product containing the resin composition.
- an additive for adding to a composition containing reinforcing fibers (A) containing carbon fibers and a matrix resin (C), for improving or improving the reinforcing effect of the reinforcing fibers (A), Contains a semi-crystalline thermoplastic resin and generates heat in a temperature range between the glass transition temperature and the melting point of the semi-crystalline thermoplastic resin when heated at a rate of 10 ° C./min by differential scanning calorimetry (DSC).
- An additive containing a resin particle (B) having a peak and an average particle diameter of 3 to 40 ⁇ m is also included.
- the reinforcing effect by the reinforcing fiber can be improved.
- the CFRP interlayer toughness can be easily improved and the handling properties are excellent.
- FIG. 1 is an endothermic curve in which the alicyclic polyamide particles obtained in Example 1 are heated by a differential scanning calorimeter (DSC) at a rate of 10 ° C./min.
- FIG. 2 is an endothermic curve obtained by heating the alicyclic polyamide particles obtained in Comparative Example 1 at a rate of 10 ° C./min by DSC.
- FIG. 3 is a chart of wide-angle X-ray diffraction of the alicyclic polyamide particles obtained in Example 1 and Comparative Example 1.
- FIG. 4 is an endothermic curve in which the polyamide 12 particles obtained in Example 2 were heated at a rate of 10 ° C./min by DSC.
- FIG. 1 is an endothermic curve in which the alicyclic polyamide particles obtained in Example 1 are heated by a differential scanning calorimeter (DSC) at a rate of 10 ° C./min.
- FIG. 2 is an endothermic curve obtained by heating the alicyclic polyamide particles obtained in Comparative Example
- FIG. 5 is a wide-angle X-ray diffraction chart of the polyamide 12 particles obtained in Example 2.
- FIG. 6 is an endothermic curve in which the polyamide 12 particles obtained in Comparative Example 3 are heated at a rate of 10 ° C./min by DSC.
- FIG. 7 is a chart of wide-angle X-ray diffraction of the polyamide 12 particles obtained in Comparative Example 3.
- FIG. 8 is a wide-angle X-ray diffraction chart of the polyamide 1010 particles obtained in Example 3.
- FIG. 9 is a wide-angle X-ray diffraction chart of the polyamide 1010 particles obtained in Comparative Example 4.
- the resin composition of the present invention contains reinforcing fibers (A), resin particles (B), and a matrix resin (resin that forms a matrix) (C). Since this resin composition can be used as a composition for obtaining a fiber reinforced composite material (or fiber reinforced resin) as described later, a composition for fiber reinforced composite material (or a composition for fiber reinforced resin). It can also be said.
- A Reinforcing fiber Reinforcing fiber (reinforcing fiber, fibrous reinforcing material, fibrous filler, fibrous filler)
- A) is a component that reinforces (or reinforces) the matrix resin, and includes carbon fibers.
- the carbon fiber (carbon fiber) is not particularly limited, and may be any of pitch-based fibers, polyacrylonitrile (PAN) -based carbon fibers, and the like. These carbon fibers can be used alone or in combination of two or more.
- the reinforcing fiber (A) may further contain a non-carbon fiber in addition to the carbon fiber.
- Non-carbon fibers include inorganic fibers (eg, glass fibers, boron fibers, aluminosilicate fibers, aluminum oxide fibers, silicon carbide fibers, metal fibers, potassium titanate fibers), organic fibers (eg, polyester fibers [eg, aromatic Group polyester fiber (for example, polyalkylene arylate fiber such as polyethylene terephthalate fiber)], polyamide fiber [for example, aromatic polyamide fiber (such as aramid fiber)], regenerated fiber (such as rayon) ⁇ .
- These non-carbon fibers can be used alone or in combination of two or more.
- the ratio of carbon fiber to the entire reinforcing fiber is, for example, 30% by volume or more, preferably 50% by volume or more, and more preferably 70%. Volume% or more (especially 90 volume% or more) may be sufficient, and 100 volume% (only carbon fiber) may be sufficient.
- the reinforcing fiber (A) may be surface-treated.
- the average diameter of the reinforcing fiber (A) depends on the type, but can be selected from a range of about 0.5 to 1000 ⁇ m (eg 1 to 500 ⁇ m), for example 1 to 300 ⁇ m (eg 2 to 100 ⁇ m), preferably 3 It may be about 70 ⁇ m, more preferably about 5 to 50 ⁇ m (especially 5 to 30 ⁇ m).
- the average diameter (average fiber diameter) of the carbon fibers is, for example, 1 to 100 ⁇ m (for example, 1.5 to 70 ⁇ m), preferably 2 to 50 ⁇ m (for example, 2.5 to 40 ⁇ m), more preferably 3 to 30 ⁇ m, particularly It may be about 5 to 20 ⁇ m (for example, 6 to 15 ⁇ m), and may usually be about 5 to 15 ⁇ m (for example, 7 to 10 ⁇ m).
- the fiber diameter can be measured by a conventional method, for example, by measuring the diameter of 10 or more fibers using an electron microscope and calculating an average value.
- the reinforcing fiber (A) may be either a short fiber or a long fiber, but may be a long fiber.
- the long fiber may be either a continuous fiber or a discontinuous fiber, or a combination of a continuous fiber and a discontinuous fiber.
- the reinforcing fiber (A) may be in the form of a cloth (or cloth).
- the fabric (fiber assembly) include woven fabric (woven fabric), non-woven fabric, and knitted fabric (knitted fabric).
- the reinforcing fiber (A) is included in the composition together with the resin particles (B) and the matrix resin (C) in a manner aligned (arranged) in the same direction (or one direction) as described later. It may be.
- the fabric structure can be appropriately selected according to the type of fabric.
- examples of the woven fabric include plain weave, twill weave and satin weave, but are not particularly limited.
- examples of the knitted fabric structure include warp knitting (for example, tricot) and weft knitting (for example, flat knitting, knitting knitting, etc.).
- the resin component that forms the resin particles (B) is a semicrystalline thermoplastic resin.
- the semi-crystalline thermoplastic resin is not particularly limited as long as it is a resin capable of improving (or assisting) the reinforcing effect of the reinforcing fiber.
- polyamide resin polyamide resin
- polyester resin for example, aromatic polyester resin such as polyethylene terephthalate
- Polyacetal resin polysulfide resin
- polysulfone resin including polyethersulfone resin
- polyetherketone resin polyolefin resin and the like.
- polyamide resins are preferred because they are particularly effective for effective reinforcement in combination with an epoxy resin as a matrix resin.
- the polyamide resin include aliphatic polyamide resins, alicyclic polyamide resins, and aromatic polyamide resins.
- the polyamide resin may be a homopolyamide or a copolyamide.
- the terminal group of the polyamide resin is not particularly limited, but may be an amino group, a carboxyl group, or an acid anhydride group.
- homopolyamide includes an aliphatic diamine component [alkane diamine (for example, C 4-16 alkylene diamine such as tetramethylene diamine, hexamethylene diamine, dodecane diamine, preferably C 6-14 alkylene diamine, More preferably C 6-12 alkylene diamine etc.)] and aliphatic dicarboxylic acid component [eg C 4-20 alkane dicarboxylic acid such as alkane dicarboxylic acid (eg adipic acid, sebacic acid, dodecanedioic acid, preferably C Homo or copolyamide, lactam [ ⁇ -caprolactam, ⁇ -laurolactam, etc.
- alkane diamine for example, C 4-16 alkylene diamine such as tetramethylene diamine, hexamethylene diamine, dodecane diamine, preferably C 6-14 alkylene diamine, More preferably C 6-12 alkylene diamine etc.
- an aminocarboxylic acid eg, a C 4-20 aminocarboxylic acid such as ⁇ -aminoundecanoic acid, preferably a C 4-16 aminocarboxylic acid, more preferably a C 6-14 aminocarboxylic acid.
- Copolyamides of a polyamide, an aliphatic diamine component and a first amide forming component of an aliphatic dicarboxylic acid component and a second amide forming component of a lactam or aminocarboxylic acid are included.
- aliphatic polyamide resin examples include polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 66, polyamide 610, polyamide 611, polyamide 612, polyamide 613, polyamide 1010, polyamide 1012, polyamide 66/11, Polyamide 66/12, polyamide 6/12/612, etc. are mentioned.
- the alicyclic polyamide resin examples include homopolyamides and copolyamides containing at least one selected from an alicyclic diamine component and an alicyclic dicarboxylic acid component as constituent components, such as diamine components and dicarboxylic acid components.
- an alicyclic polyamide obtained using alicyclic diamine and / or alicyclic dicarboxylic acid can be used as at least a part of the components.
- the diamine component and dicarboxylic acid component it is preferable to use the aliphatic diamine component and / or aliphatic dicarboxylic acid component exemplified above together with the alicyclic diamine component and / or alicyclic dicarboxylic acid component.
- Such an alicyclic polyamide resin has high transparency and is known as a so-called transparent polyamide.
- Examples of the alicyclic diamine component include diaminocycloalkanes such as diaminocyclohexane (diamino C 5-10 cycloalkanes); bis (4-aminocyclohexyl) methane, bis (4-amino-3-methylcyclohexyl) methane, 2, Bis (aminocycloalkyl) alkanes such as 2-bis (4′-aminocyclohexyl) propane [bis (aminoC 5-8 cycloalkyl) C 1-3 alkanes and the like]; hydrogenated xylylenediamine and the like.
- diaminocycloalkanes such as diaminocyclohexane (diamino C 5-10 cycloalkanes); bis (4-aminocyclohexyl) methane, bis (4-amino-3-methylcyclohexyl) methane, 2, Bis (aminocycloalkyl) al
- the alicyclic diamine component has a substituent such as an alkyl group (a C 1-6 alkyl group such as a methyl group or an ethyl group, preferably a C 1-4 alkyl group, more preferably a C 1-2 alkyl group). It may be.
- alkyl group a C 1-6 alkyl group such as a methyl group or an ethyl group, preferably a C 1-4 alkyl group, more preferably a C 1-2 alkyl group.
- the alicyclic dicarboxylic acid include cycloalkane dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid and 1,3-cyclohexanedicarboxylic acid (C 5-10 cycloalkane-dicarboxylic acid and the like).
- Typical alicyclic polyamide resins include, for example, an alicyclic diamine component [eg, bis (aminocyclohexyl) alkane and the like] and an aliphatic dicarboxylic acid component [eg, alkane dicarboxylic acid (eg, C 4-20 alkane- Condensates with dicarboxylic acid components etc.].
- an alicyclic diamine component eg, bis (aminocyclohexyl) alkane and the like
- an aliphatic dicarboxylic acid component eg, alkane dicarboxylic acid (eg, C 4-20 alkane- Condensates with dicarboxylic acid components etc.].
- the aromatic polyamide resin includes an aliphatic polyamide resin in which at least one of an aliphatic diamine component and an aliphatic dicarboxylic acid component is an aromatic component, for example, a polyamide in which a diamine component is an aromatic diamine component [
- a condensate of an aromatic diamine such as metaxylylenediamine
- an aliphatic dicarboxylic acid for example, MXD-6 or the like
- a polyamide whose dicarboxylic acid component is an aromatic component for example, an aliphatic diamine (trimethyl) Hexamethylenediamine, etc.
- aromatic dicarboxylic acids terephthalic acid, isophthalic acid, etc.
- the aromatic polyamide resin may be a wholly aromatic polyamide (aramid) such as a polyamide [poly (m-phenyleneisophthalamide) or the like] in which the diamine component and the dicarboxylic acid component are aromatic components.
- semi-crystalline polyamide resins may be used alone or in combination of two or more.
- semi-crystalline polyamides polyamides having crystallinity
- alicyclic polyamides and aliphatic polyamides are preferred (alicyclic polyamides and / or aliphatic polyamides) from the viewpoint of a large reinforcing effect of the matrix resin.
- An alicyclic polyamide resin (a polyamide resin having an alicyclic structure) is particularly preferable from the viewpoint that the resin particles (B) are easily distributed in the vicinity of the reinforcing fiber (A).
- the number average molecular weight of the semicrystalline thermoplastic resin may be, for example, about 8000 to 200000, preferably 9000 to 150,000, and more preferably about 10,000 to 100,000.
- the number average molecular weight can be measured by gel permeation chromatography using polystyrene or the like as a standard substance.
- the melting point of the semicrystalline thermoplastic resin is not particularly limited, but a polyamide resin having a relatively high melting point may be suitably used.
- a semi-crystalline polyamide resin can easily obtain the reinforcing effect by the reinforcing fiber (A) because the spherical shape is easily maintained at a high level in the production of the composition or the molded product.
- the melting point of such a semicrystalline polyamide resin is, for example, 150 ° C. or higher (eg, 155 to 350 ° C.), preferably 160 ° C. or higher (eg, 165 to 300 ° C.), More preferably, it may be 170 ° C.
- the melting point (or softening point) of the semicrystalline polyamide resin is equal to or higher than the molding temperature of the composition [for example, the curing temperature of a curable resin (eg, epoxy resin) as a matrix resin]. Higher temperature). If the melting point is too high, the reinforcing effect of the reinforcing fiber (A) may not be improved.
- the glass transition temperature of the semicrystalline thermoplastic resin may be, for example, 30 ° C. or higher (eg, about 40 to 200 ° C.), and in particular, the glass transition temperature of the alicyclic polyamide resin. May be 100 ° C. or higher (eg, 105 to 200 ° C.), preferably 110 ° C. or higher (eg, 115 to 180 ° C.), more preferably 120 ° C. or higher (eg, 125 to 150 ° C.).
- the transition temperature may be 30 ° C. or higher (eg, 30 to 150 ° C.), preferably 40 ° C. or higher (eg, 40 to 120 ° C.), more preferably 45 ° C. or higher (eg, 45 to 100 ° C.). If the glass transition temperature is too high, the reinforcing effect of the reinforcing fiber (A) may not be improved.
- the degree of crystallinity of the semicrystalline thermoplastic resin can be selected depending on the type of the resin, and is 80% or less (for example 75 to 1%), preferably 50% or less (for example 50 to 10%).
- the semicrystalline thermoplastic resin is an alicyclic polyamide resin
- the crystallinity may be 40% or less, for example, 30 to 1%, preferably 20 to 1%, more preferably about 20 to 5%. It is.
- the degree of crystallinity of the semicrystalline aliphatic polyamide having C 6-10 alkane units such as polyamide 1010 may be 50% or less, for example 50 to 1%, preferably 45 to 10%, more preferably 43 to It is about 30%.
- the degree of crystallinity of the semicrystalline aliphatic polyamide having a C 11-13 alkane unit such as polyamide 12 may be 80% or less, for example 80 to 10%, preferably 78 to 30%, more preferably 75 to About 35%. If the crystallinity is too high, the reinforcing effect of the reinforcing fiber (A) may not be improved.
- the degree of crystallinity can be measured by a conventional method such as an X-ray diffraction method or a differential scanning calorimetry (DSC) method, and in particular, based on wide-angle X-ray diffraction (WAXD) described in Examples described later. Can be measured.
- the resin particles (B) have an exothermic peak in the temperature range between the glass transition temperature and the melting point of the semicrystalline thermoplastic resin when the temperature is raised at a rate of 10 ° C./min by differential scanning calorimetry (DSC).
- the exothermic peak may be in the above temperature range, for example, may be at a position 1 to 70 ° C. higher than the glass transition temperature, preferably 1 to 60 ° C., more preferably 1 to 50 ° C. (especially 1 to 40 ° C.). It may be at a position as high as (° C.).
- the matrix resin (C) especially thermosetting resin such as epoxy resin.
- the reinforcing effect of the fiber (A) can be improved.
- the crystal structure of the semicrystalline thermoplastic resin constituting the resin particle (B) is not particularly limited.
- the crystal structure of the semicrystalline polyamide resin is any of ⁇ -type, ⁇ -type, and ⁇ + ⁇ -type crystal structures.
- a semicrystalline aliphatic polyamide resin in particular, a semicrystalline aliphatic polyamide having a C 11-13 alkane unit such as polyamide 12
- the shape of the resin particles (B) is preferably spherical.
- the specific surface area decreases as the sphericity increases, the specific surface area may be used as a true spherical index in the present specification and claims.
- the BET specific surface area is, for example, 1 m 2 / g or less, preferably 0.5 m 2 / g or less, more preferably 0.4 m 2 / g or less. There may be.
- the theoretical minimum specific surface area of resin particles having a specific gravity of 1.0 and an average particle diameter of 20 ⁇ m is 0.15 m 2 / g.
- an indefinite shape, a potato shape, a spherical shape, and the like are known, but such a shape is usually determined depending on a method for producing the particle.
- the average particle diameter (average particle diameter) of the resin particles (B) can be selected from the range of 3 ⁇ m or more (for example, 3 to 85 ⁇ m), for example, 3 to 40 ⁇ m, preferably 5 to 35 ⁇ m, more preferably 10 to 30 ⁇ m (particularly 15 to 15 ⁇ m). About 25 ⁇ m). If the average particle size is too small, the reinforcing effect of the reinforcing fiber (A) may not be improved.
- the average particle diameter is represented by a number average primary particle diameter, and can be measured by a laser diffraction scattering method or the like.
- the resin particles (B) are, for example, resin particles having a particle diameter in the range of 3 to 40 ⁇ m (particularly 15 to 25 ⁇ m), based on the number of particles, 50% or more (for example, 60% or more),
- the resin particles may preferably be 70% or more, more preferably 80% or more, and particularly 90% or more.
- the average particle diameter of the resin particles (B) can be selected according to the average diameter of the reinforcing fibers (A).
- the average particle diameter (average fiber diameter) of the reinforcing fibers (A) is 0.5 to 15 times ( For example, 0.7 to 12 times), preferably 1 to 10 times (for example, 1.5 to 5 times), more preferably about 2 to 4 times (especially 2.5 to 3.5 times), Usually, it may be about 1.5 to 15 times (for example, 2 to 10 times).
- the resin particles (B) may contain a semicrystalline thermoplastic resin, but may further contain an impact modifier.
- the impact modifier include acid-modified polyolefin resins (acid-modified polyolefin resins) and resins having an epoxy group-containing group such as a glycidyl group. These impact modifiers can be used alone or in combination of two or more. Of these impact modifiers, acid-modified polyolefin resins are preferred, and the polyolefin resins may partially have carbon-carbon double bonds.
- the proportion of the impact modifier is, for example, about 1 to 30 parts by weight, preferably about 1 to 25 parts by weight, and more preferably about 5 to 20 parts by weight with respect to 100 parts by weight of the semicrystalline thermoplastic resin.
- Resin particles (B) may further contain other thermoplastic resins and conventional additives as other components.
- conventional additives include stabilizers, fillers (non-fibrous fillers), colorants, dispersants, preservatives, antioxidants, antifoaming agents, and the like. These other components may be used alone or in combination of two or more. The total proportion of other components may be, for example, 10 parts by weight or less (for example, about 0.01 to 10 parts by weight) with respect to 100 parts by weight of the semicrystalline thermoplastic resin.
- the matrix resin (C) is a resin component that becomes a matrix of the reinforcing fibers (A) [further, the resin particles (B)], and can be appropriately selected depending on the application and desired characteristics.
- Such a matrix resin (C) includes a resin (resin component).
- the resin can be selected according to the application and desired properties or physical properties, and is a thermoplastic resin [for example, acrylic resin, polyolefin resin (for example, polypropylene), polyamide resin (for example, the above exemplified polyamide resin), polyester resin (for example, , Aromatic polyester resins such as polyethylene terephthalate), polycarbonate resins, polyphenylene ether resins, polyphenylene sulfide resins, polysulfone resins, polyether ketone resins, polyether ether ketone resins, polyimide resins, polyetherimide resins, etc.], curable resins Any of (thermal or photocurable resin) may be used.
- the resins may be used alone or in combination of two or more.
- thermosetting resin can be suitably used in combination with the resin particles (B) from the viewpoint of strength and thermal characteristics. Therefore, the matrix resin may contain a thermosetting resin.
- thermosetting resin examples include epoxy resin, unsaturated polyester resin, vinyl ester resin, acrylic resin, phenol resin, urea resin, melamine resin, aniline resin, polyimide resin, bismaleimide resin, and the like. These thermosetting resins may be used alone or in combination of two or more.
- an epoxy resin is particularly preferable.
- the epoxy resin include glycidyl ether type epoxy resin, glycidyl amine type epoxy resin (for example, tetraglycidyldiaminodiphenylmethane, triglycidyl-p-aminophenol, triglycidylaminocresol, diglycidylaniline, N, N-diglycidyl-4 -Glycidyloxyaniline, etc.), glycidyl ester type epoxy resins [eg dicarboxylic acids (eg aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid or hydrogenated products thereof) Diglycidyl ester, etc.], alkene oxides (eg, vinylcyclohexene dioxide, etc.), triglycidyl isocyanurate and the like.
- dicarboxylic acids
- glycidyl ether type epoxy resin examples include bisphenol type epoxy resins (bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol S type epoxy resins, brominated bisphenol type epoxy resins and the like, and alkylene oxide adducts thereof) Reacted with epichlorohydrin), phenol type epoxy resin (phenol novolak type epoxy resin, cresol novolak type epoxy resin, naphthol novolak type epoxy resin, bisphenol A novolak type epoxy resin, bisphenol F novolak type epoxy resin, biphenyl skeleton containing Phenol novolac resin, xylylene skeleton-containing phenol novolak resin, etc.), dicyclopentadiene type epoxy resin, naphthalene skeleton Epoxy resins having an aromatic skeleton such as glycidyl ether [for example, di (glycidyloxy) naphthalene such as 1,5-di (glycidyloxy) naphthalene, bis [
- the number of moles of alkylene oxide added per mole of hydroxyl group of the bisphenol is, for example, 1 mole or more (for example, 1 to 20 moles), preferably 1 to 15 moles, more preferably 1 It may be about ⁇ 10 mol.
- epoxy resins may be used alone or in combination of two or more.
- an epoxy resin having an aromatic skeleton such as a bisphenol type epoxy resin, is preferable in terms of strength and the like. Therefore, the epoxy resin may be composed of at least an epoxy resin having an aromatic skeleton, or an epoxy resin having an aromatic skeleton and another epoxy resin (for example, an epoxy resin having an aliphatic skeleton) may be combined. Good.
- the epoxy resin is a monofunctional epoxy compound (or diluent) ⁇ for example, monoglycidyl ether [for example, alkyl glycidyl ether (for example, 2-ethylhexyl glycidyl ether), alkenyl glycidyl ether (for example, allyl glycidyl)
- the epoxy resin may be combined with an alkene oxide (for example, octylene oxide, styrene oxide, or the like) ⁇ , an aryl glycidyl ether (for example, phenyl glycidyl ether, etc.), or the like.
- the ratio of the former / the latter for example 99/1 to 50/50, preferably 97/3 to 60/40, more preferably May be about 95/5 to 70/30.
- the epoxy resin (or composition with the epoxy resin and the monofunctional epoxy compound) may be solid or liquid at room temperature (for example, about 20 to 30 ° C.).
- the viscosity (25 ° C.) of the liquid epoxy resin is, for example, 50 to 50000 mPa ⁇ s, preferably 100 to 40000 mPa ⁇ s (eg 200 to 35000 mPa ⁇ s), and more preferably 300 to 30000 mPa ⁇ s (eg 500 to 25000 mPa ⁇ s) or 1000 mPa ⁇ s or more (for example, 2000 to 50000 mPa ⁇ s, preferably 3000 to 30000 mPa ⁇ s, more preferably 5000 to 25000 mPa ⁇ s).
- the matrix resin may contain a curing agent or a curing accelerator. That is, the matrix resin may be composed of a resin (thermosetting resin) and a curing agent or curing accelerator for this resin.
- the curing agent can be appropriately selected according to the type of resin.
- the curing agent when the resin is an epoxy resin, for example, an amine-based curing agent, a phenol resin-based curing agent (for example, a phenol novolak resin, cresol). Novolak resins, etc.), acid anhydride-based curing agents [eg, aliphatic dicarboxylic anhydrides (such as dodecenyl succinic anhydride), alicyclic dicarboxylic anhydrides (tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, etc.
- aliphatic dicarboxylic anhydrides such as dodecenyl succinic anhydride
- alicyclic dicarboxylic anhydrides tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, hexahydrophthalic anhydride, etc.
- aromatic dicarboxylic anhydrides phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, benzophenone tetracarboxylic anhydride, etc.
- polymercaptan curing agents polymercaptan curing agents
- latent curing agents trifluoride
- Boron-amine complexes dicyandiamide, carboxylic acid hydrazide, etc.
- amine-based curing agent examples include aromatic amine-based curing agents [eg, polyaminoarene (eg, diaminoarene such as paraphenylenediamine, metaphenylenediamine), polyamino-alkylarene (eg, diamino-alkyl such as diethyltoluenediamine).
- aromatic amine-based curing agents eg, polyaminoarene (eg, diaminoarene such as paraphenylenediamine, metaphenylenediamine), polyamino-alkylarene (eg, diamino-alkyl such as diethyltoluenediamine).
- Group amine curing agents for example, ethylenediamine, hexamethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, diethylaminopropylamine, etc.
- alicyclic amine curing agents for example, mensendiamine, isophoronediamine, bis ( 4-amino-3-methylcyclo Xyl) methane, 3,9-bis (3-aminopropyl) -2,4,8,10-tetraoxaspiro [5.5] undecane, norbornanediamine, etc.
- imidazoles for example, 2-methylimidazole, 2 -Alkyl imidazoles such as phenylimidazole, 2-heptadecylimidazole, 2-ethyl-4-methylimidazole; 2-phenylimidazole, 2-phenyl-4-methylimidazole, 2-phenyl-4-methyl-5-hydroxymethyl Arylimidazoles such as imi
- the curing agents may be used alone or in combination of two or more.
- the curing agent may act as a curing accelerator.
- amine-based curing agents for example, aromatic amine-based curing agents
- aromatic amine-based curing agents may be suitably used.
- the proportion of the curing agent can be appropriately selected according to the type of epoxy resin (epoxy equivalent, etc.), the type of curing agent, and the like.
- 0.1 to 300 parts by weight preferably 1 to 100 parts by weight of the epoxy resin. It may be about 250 parts by weight, more preferably 3 to 200 parts by weight (for example, 4 to 150 parts by weight), particularly about 5 to 100 parts by weight.
- the curing accelerator can also be appropriately selected according to the type of resin.
- the curing accelerator when the resin is an epoxy resin, for example, phosphines (for example, ethylphosphine, propylphosphine, trialkylphosphine, phenylphosphine) , Triphenylphosphine, etc.), amines (for example, triethylamine, piperidine, benzyldimethylamine, triethanolamine, dimethylaminoethanol, triethylenediamine, tris (dimethylaminomethyl) phenol, N, N-dimethylpiperazine, etc. And tertiary amines or salts thereof).
- the curing accelerators may be used alone or in combination of two or more.
- the proportion of the curing accelerator can be appropriately selected depending on the type of the curing agent, but for example, 0.01 to 100 parts by weight, preferably 0.05 to 50 parts by weight, more preferably 100 parts by weight of the epoxy resin. May be about 1 to 30 parts by weight.
- the resin particles (B) and the resin particles (B) and the matrix resin (C) (the total amount with the resin when a curing agent or a curing accelerator is included) (B )
- B Can be selected from a range of 50% by weight or less (for example, about 0.1 to 40% by weight), for example, 30% by weight or less (for example, 0.5 to 25% by weight), preferably 20% by weight or less (for example, 1 -18% by weight), more preferably 15% by weight or less (eg 2-12% by weight), or 10% by weight or less (eg 0.5-8% by weight, preferably 1-5% by weight). It may be.
- the resin with respect to the total amount of the resin particles (B) and the matrix resin (C) (the total amount with the resin when a curing agent or a curing accelerator is included).
- the ratio of the particles (B) can be selected from the range of 30% by volume or less (eg, about 0.01 to 25% by volume), for example, 20% by volume or less (eg, 0.1 to 15% by volume), preferably 10% by volume. % Or less (for example, 0.3 to 8% by volume), more preferably about 5% by volume or less (for example, 0.5 to 3% by volume).
- the reinforcing effect by the reinforcing fibers can be sufficiently obtained.
- the ratio of the total amount of the resin particles (B) and the matrix resin (C) is, for example, 1 to 70 weights with respect to 100 parts by weight of the reinforcing fibers (A). Part, preferably 2 to 50 parts by weight, more preferably about 3 to 30 parts by weight.
- composition of the present invention may contain other components as necessary as long as the effects of the present invention are not impaired.
- the other components can be appropriately selected depending on the application, and examples include stabilizers, fillers (non-fibrous fillers), colorants, dispersants, preservatives, antioxidants, antifoaming agents, and the like. It is done. These other components may be used alone or in combination of two or more.
- composition of this invention may contain the electroconductive particle, and does not necessarily need to contain electroconductive particle normally.
- the form of the composition of the present invention only needs to contain reinforcing fibers (A), resin particles (B) and matrix resin (C) (and other components as necessary, the same shall apply hereinafter).
- the fiber (A) may be impregnated (attached) with a mixture containing the resin particles (B) and the matrix resin (C) [or a matrix resin (C) containing the resin particles (B)].
- Such a form can also be said to be a form in which the reinforcing fibers (A) and the resin particles (B) are dispersed in the matrix resin (C).
- such a composition may be a prepreg (molding intermediate material).
- the matrix resin (C) is a thermosetting resin component [for example, an epoxy resin component (such as a composition of an epoxy resin and a curing agent)]
- the composition may be semi-cured.
- a specific form can be selected according to the shape of the reinforcing fiber (A).
- a plurality of reinforcing fibers (A) aligned in the same direction (or one direction) are impregnated with the mixture.
- examples thereof include (ii) a form in which the above-mentioned mixture is impregnated into the cloth-like reinforcing fibers (A).
- the prepreg is known as a UD prepreg
- the prepreg in the composition in the form (ii) is known as a cross prepreg.
- composition is obtained by melting and kneading a semicrystalline thermoplastic resin and an aqueous medium incompatible with the resin, and then removing the aqueous medium with a hydrophilic solvent from the obtained melt-kneaded product. It is obtained through an impregnation step of impregnating the obtained resin particles (B) and matrix resin (C) into the resin particle production step of obtaining (B) and the reinforcing fibers (A).
- the resin particles (B) are obtained by a conventional forced emulsification method in which the resin particles are melt kneaded with the aqueous medium.
- a conventional forced emulsification method in which the resin particles are melt kneaded with the aqueous medium.
- semi-crystalline resin particles having a specific degree of crystallinity are prepared under conditions different from those of conventional methods (particularly, drying treatment at a low temperature). Is obtained.
- a conventional method for example, the method described in JP-A No. 2010-132911 can be used.
- the aqueous medium can be selected according to the type of semicrystalline thermoplastic resin, for example, hot-melt saccharides (oligosaccharides such as sucrose and maltotriose; sugar alcohols such as xylitol, erythritol, sorbitol, mannitol, etc.) ), Water-soluble polymers (water-soluble synthetic polymers such as polyethylene glycol, polyvinyl alcohol, sodium polyacrylate, and polyacrylamide; polysaccharides such as starch and methyl cellulose). These aqueous media can be used alone or in combination of two or more.
- hot-melt saccharides oligosaccharides such as sucrose and maltotriose; sugar alcohols such as xylitol, erythritol, sorbitol, mannitol, etc.
- Water-soluble polymers water-soluble synthetic polymers such as polyethylene glycol, polyvinyl alcohol, sodium polyacrylate, and polyacrylamide; polysacchari
- the aqueous medium may be a water-soluble polymer (for example, a water-soluble synthetic polymer such as polyethylene glycol or polyvinyl alcohol).
- a water-soluble synthetic polymer such as polyethylene glycol or polyvinyl alcohol.
- polyethylene glycol “PEG-20000”, “PEG-11000”, “PEG-1000”, “PEG-200” manufactured by NOF Corporation are used alone or in combination of two or more. it can.
- the viscosity of the aqueous medium is one factor for controlling the particle size of the resin particles obtained by the forced emulsification method, and the selection of the viscosity depends on the target particle size, the type and molecular weight of the semicrystalline thermoplastic resin, Depending on the volume ratio between the semicrystalline thermoplastic resin and the aqueous medium, the shear rate (shear rate) at the time of compounding, etc., these conditions may be combined and adjusted.
- the aqueous medium may be polyethylene glycol, in particular, because it can be easily adjusted to an appropriate particle size.
- the weight ratio of the aqueous medium may be, for example, about 10 to 100 parts by weight, preferably about 20 to 100 parts by weight, and more preferably about 30 to 100 parts by weight with respect to 100 parts by weight of the semicrystalline thermoplastic resin.
- the volume ratio of the aqueous medium may be 50% by volume or more (eg, about 50 to 90% by volume) with respect to the total volume of the aqueous medium and the semicrystalline thermoplastic resin. If the proportion of the aqueous medium is too large, the productivity may be reduced. Conversely, if the proportion is too small, it may be difficult to produce resin particles having a small particle size.
- the melt kneading temperature may be a temperature not lower than the melting point or softening point of the semicrystalline thermoplastic resin, and can be selected according to the type of the semicrystalline thermoplastic resin.
- an alicyclic polyamide resin for example, 250 Or higher (eg 250 to 350 ° C.), preferably 260 to 320 ° C., more preferably about 270 to 300 ° C.
- the cooling method after melt-kneading is not particularly limited, from the viewpoint of productivity, when the semi-crystalline thermoplastic resin is a polyamide resin (particularly an alicyclic polyamide resin), it is forcibly cooled (rapidly cooled).
- the cooling rate may be 1 ° C./min or more (eg, about 1 to 10 ° C./min).
- the effect on the crystallinity of the resin particles is small, but in the case of a polyamide resin (for example, alicyclic polyamide resin) having a low crystallization rate, it may be forcibly cooled. .
- a method for removing the aqueous medium from the cooled kneaded product a method using a hydrophilic solvent is used, and the aqueous medium is usually removed by washing with a hydrophilic solvent.
- a hydrophilic solvent for example, water, alcohol (such as lower alcohol such as ethanol), water-soluble ketone (such as acetone) and the like can be preferably used.
- the drying method of the resin particles obtained by removing the aqueous medium it is preferable to dry at a low temperature from the viewpoint of suppressing excessive crystallization.
- the crystallinity of the resin particles varies depending on the type of resin and aqueous medium, process temperature, cooling method, drying method after removing the aqueous medium, and the like. There are various combinations of these factors, and it is difficult to simply define the conditions for obtaining a semi-crystalline resin with low crystallinity. Among these factors, the influence of the drying method is particularly large.
- the drying temperature can be selected according to the type of the semicrystalline thermoplastic resin, and may be (Tg + 40) ° C. or lower, for example, (Tg + 30) ° C., when the glass transition temperature of the semicrystalline thermoplastic resin is Tg.
- it is preferably (Tg + 20) ° C. or less, more preferably (Tg + 10) ° C. or less, and in particular, it may be a glass transition temperature or less under reduced pressure.
- the drying temperature may be equal to or lower than the glass transition temperature, for example, (Tg-50) ° C.
- the drying temperature may be not higher than the glass transition temperature, and may be, for example, about Tg ° C. to (Tg + 40) ° C., preferably about (Tg + 10) ° C. to (Tg + 35) ° C.
- the reinforcing fiber (A), the resin particles (B), and the matrix resin (C) can be mixed, and the reinforcing fiber (A) usually contains the resin particles (B) and the matrix resin (C). It can be produced by impregnating (or adhering) the mixture.
- the liquid mixture may be a liquid (liquid at normal temperature) matrix resin (C) or an appropriate solvent (a poor solvent for the resin particles (B)). Moreover, a liquid mixture can also be obtained by melting the matrix resin (C).
- the molded article of the said composition (molded article formed with the said composition) is also contained in this invention. Since such a molded article includes the reinforcing fiber (A) and the matrix resin (C) in which the reinforcing fiber (A) is dispersed, the composite material [fiber reinforced composite material (particularly, carbon fiber composite material)]. It can also be said.
- the manufacturing method (molding method) of the molded product can be selected according to the form of the composition and the kind of the constituent components.
- the matrix resin (C) is a thermosetting resin component
- the composition is cured to form a molded product.
- the matrix resin (C) is a thermosetting resin component
- the molding method can also be selected depending on whether the thermosetting resin component is uncured or semi-cured.
- the shape of the molded product may be any one of a one-dimensional shape (such as a rod), a two-dimensional shape (such as a sheet), and a three-dimensional shape.
- Specific molding methods include hand lay-up molding method, SMC (sheet molding compound) press molding method, RIMP (resin infusion) molding method, prepreg press molding method, prepreg autoclave method, winding method (filament winding method, pin Winding molding method), pultrusion molding method, BMC (bulk molding compound) molding method and the like.
- the reinforcing function for example, interlayer toughness
- the reinforcing fiber (A) can be efficiently reinforced by the resin particles (B).
- the resin particles (B) having a specific shape and particle size, and even if the proportion of the resin particles (B) is relatively small, it is sufficient. Can be realized.
- Alicyclic PA alicyclic polyamide, “Trogamide CX7323” manufactured by Daicel-Evonik Co., Ltd., melting point 247 ° C.
- Alicyclic PA particles Polyamide 12 particles obtained by the chemical pulverization method shown below (method of dissolving in a solvent and then reprecipitating into powder) In an 1000 mL pressure-resistant glass autoclave, alicyclic polyamide (Daicel) Ebonic Co., Ltd. “Trogamide CX7323” 18 g, polyvinyl alcohol (Nippon Synthetic Chemical Co., Ltd. “GOHSENOL GM-14”) 32 g, N-methyl-2-pyrrolidone 300 g as an organic solvent was added, and 99% by volume After performing the above nitrogen substitution, it heated at 180 degreeC and stirred for 4 hours until the polymer melt
- PA12 Polyamide 12, "Vestamide L1600” manufactured by Daicel Evonik Co., Ltd.
- PA12 particles Polyamide 12 particles obtained by chemical pulverization method, “Best Ginto 2158” manufactured by Daicel-Evonik Co., Ltd.
- PA1010 Polyamide 1010, “Vestamide Terra BS 1393” manufactured by Daicel Evonik Co., Ltd.
- Amorphous PA Aromatic polyamide, “Trogamide T5000” manufactured by Daicel Evonik Co., Ltd.
- Matrix resin Mixture of epoxy resin (Mitsubishi Chemical Corporation, “jER828”) and amine-based curing agent (Mitsubishi Chemical Corporation, “jER Cure W”) Carbon fiber: HONLU TECHNOLOGY CO. LTD “TC-33”, average fiber diameter of about 7 ⁇ m.
- the obtained resin particles were dispersed in water and measured using a laser diffraction / scattering particle size distribution measuring device (“LA920” manufactured by Horiba, Ltd.).
- Crystallinity [total integrated intensity of crystal diffraction peaks (cps ⁇ deg)] / [total integrated intensity of crystal diffraction peaks and amorphous halo (cps ⁇ deg)] ⁇ 100%.
- Example 1 Manufacture of resin particles
- the alicyclic PA was microparticulated by the forced emulsification method according to the examples of JP-A-2010-13281.
- the melt-kneaded product extruded from the die of the extruder is forcibly cooled using a spot cooler, and then only polyethylene glycol is removed by washing with water, followed by drying under reduced pressure at 120 ° C. for 24 hours to obtain resin particles (powder) )
- the average particle diameter of the resin particles was 21 ⁇ m, and a crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- a chart (sound absorption curve) by DSC is shown in FIG. As is clear from FIG. 1, a large peak due to crystallization can be confirmed at around 170 ° C., and since the degree of crystallization is low, it can be confirmed that the obtained particles have low crystallinity.
- the new woven fabric is laminated and impregnated with the matrix resin. The operation was repeated to obtain a 12-layer laminate.
- a total of 13 layers of two types that is, a laminate obtained by laminating 12 layers of fabric, and 12 layers of fabric and 1 layer of polyimide film (“Kapton” manufactured by Toray DuPont Co., Ltd.) were laminated.
- a laminate (a laminate in which a polyimide film having a thickness of 25 ⁇ m was inserted at the time of lamination of the sixth layer in order to make a pre-crack) was prepared.
- each laminate was placed in a thermostatic bath under a pressure of about 8 MPa, and allowed to stand at 100 ° C. for 2 hours and at 175 ° C. for 4 hours to perform a curing treatment.
- cured material was about 2.8 mm.
- the laminated body containing a polyimide film pulled out the polyimide film after hardening. Then, it cut into the shape of length 140mm * width 25mm * thickness 2.8mm with the diamond cutter.
- test piece B Resin particles were added at 20% by weight with respect to the matrix resin, and a test B having a shape conforming to ISO 179 / 1eA was produced.
- Comparative Example 1 A test piece was prepared in the same manner as in Example 1 using alicyclic PA particles obtained by a chemical pulverization method as resin particles.
- the average particle diameter of the resin particles was 23 ⁇ m, and no crystallization peak was observed under a temperature rising condition by DSC of 10 ° C./min.
- FIG. 2 shows a DSC chart (sound absorption curve). As is apparent from FIG. 2, no peak due to crystallization was observed at around 170 ° C., and it was confirmed that the obtained particles were highly crystalline.
- FIG. 3 shows a wide-angle X-ray chart of the alicyclic polyamide particles obtained in Example 1 and Comparative Example 1.
- the alicyclic polyamide particles obtained in Example 1 have a gentle mountain shape, low crystallinity, and the crystal form could not be confirmed.
- Comparative Example 2 In the production of resin particles, the melt-kneaded product was allowed to cool naturally without using a spot cooler, and after removing polyethylene glycol, it was dried by heating at 180 ° C. for 3 hours without drying under reduced pressure. A test piece was prepared in the same manner. The average particle diameter of the resin particles was 23 ⁇ m, and no crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC, and the crystallization degree was high.
- Example 2 In the production of resin particles, instead of alicyclic PA and polyethylene glycol, PA12 and sugar are used, and the melt-kneaded product is allowed to cool naturally without using a spot cooler.
- a test piece was prepared in the same manner as in Example 1 except that it was dried by heating at 80 ° C. for 3 hours.
- the average particle diameter of the resin particles was 20 ⁇ m, and a crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- a chart (sound absorption curve) by DSC is shown in FIG. As is apparent from FIG. 4, a peak due to crystallization was confirmed at around 170.degree.
- Comparative Example 3 A test piece was prepared in the same manner as in Example 1 using PA12 particles obtained by a chemical pulverization method as resin particles. The average particle diameter of the resin particles was 24 ⁇ m, and no crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- Example 3 In the production of resin particles, instead of alicyclic PA and polyethylene glycol, PA1010 and sugar are used, the melt-kneaded product is allowed to cool naturally without using a spot cooler, and after removing the sugar, it is not dried under reduced pressure.
- a test piece was prepared in the same manner as in Example 1 except that it was dried by heating at 80 ° C. for 3 hours.
- the average particle size of the resin particles was 22 ⁇ m, and a crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- Example 4 A test piece was prepared in the same manner as in Example 1 except that polyvinyl alcohol was used instead of polyethylene glycol in the production of the resin particles.
- the average particle diameter of the resin particles was 11 ⁇ m, and a crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- Example 5 In the production of resin particles, instead of alicyclic PA and polyethylene glycol, PA12 and sugar are used, and the melt-kneaded product is allowed to cool naturally without using a spot cooler. A test piece was prepared in the same manner as in Example 1 except that it was dried by heating at 80 ° C. for 3 hours. The average particle diameter of the resin particles was 5 ⁇ m, and a crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- Comparative Example 5 In the production of resin particles, a test piece was prepared in the same manner as in Example 1 except that amorphous PA was used instead of alicyclic PA, and after polyethylene glycol was removed, drying was performed at 140 ° C. for 24 hours by vacuum drying. Produced. The average particle diameter of the resin particles was 19 ⁇ m, and no crystallization peak was observed under a temperature rising condition of 10 ° C./min by DSC.
- Comparative Example 6 A test piece was produced without using resin particles.
- Table 1 shows the results of evaluation of the resin particles and test pieces obtained in Examples and Comparative Examples.
- the resin particles have a crystallization peak, and the interlayer toughness and impact strength are high, whereas in the comparative example, the resin particles do not have a crystallization peak. Interlaminar toughness is also low.
- the resin composition of the present invention can be used as a composition for fiber-reinforced composite materials.
- Such composite materials are structural members (structural materials) in various fields, such as vehicles (for example, airplanes, helicopters, rockets, automobiles, motorcycles, bicycles, trains, ships, wheelchairs, etc.), artificial satellites, windmills, sports. It can be applied to products (golf shafts, tennis rackets), casings (notebook PC casings, etc.), medical products (artificial bones, etc.), IC trays, suspension rods, piers, etc.
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Abstract
Description
本発明の樹脂組成物は、強化繊維(A)、樹脂粒子(B)及びマトリックス樹脂(マトリックスを形成する樹脂)(C)を含む。この樹脂組成物は、後述のように、繊維強化複合材料(又は繊維強化樹脂)を得るための組成物として用いることができるため、繊維強化複合材料用組成物(又は繊維強化樹脂用組成物)ということもできる。
強化繊維(補強繊維、繊維状強化材、繊維状フィラー、繊維状充填剤)(A)は、マトリックス樹脂を補強(又は強化)する成分であり、炭素繊維を含む。炭素繊維(カーボン繊維)は、特に限定されず、ピッチ系繊維、ポリアクリロニトリル(PAN)系炭素繊維などのいずれであってもよい。これらの炭素繊維は、単独で又は二種以上組み合わせて使用できる。
樹脂粒子(B)を形成する樹脂成分は、半結晶性熱可塑性樹脂である。半結晶性熱可塑性樹脂としては、強化繊維の補強効果を向上(又は補助)できる樹脂であれば特に限定されず、例えば、ポリアミド樹脂、ポリエステル樹脂(例えば、ポリエチレンテレフタレートなどの芳香族ポリエステル樹脂など)、ポリアセタール樹脂、ポリスルフィド樹脂、ポリスルホン樹脂(ポリエーテルスルホン樹脂を含む)、ポリエーテルケトン樹脂、ポリオレフィン樹脂などが挙げられる。これらの半結晶性熱可塑性樹脂は、単独で又は2種以上組み合わせてもよい。
α型結晶構造:2つのピークを有する急峻な山形状
γ型結晶構造:1つのピークを有する急峻な山形状(例えば、2θ=21.5°±0.2°に1つのピークを有する山形状)
α+γ型結晶構造:2θ=α型の2つのピークと、α型の2つのピークの間に存在するγ型のピークとが混在した3つのピークを有する急峻な山形状。
マトリックス樹脂(C)は、強化繊維(A)[さらには樹脂粒子(B)]のマトリックスとなる樹脂成分であり、用途や所望の特性に応じて、適宜選択できる。
本発明の組成物の形態は、強化繊維(A)、樹脂粒子(B)及びマトリックス樹脂(C)(さらには必要に応じて他の成分、以下同じ)を含んでいればよく、通常、強化繊維(A)に、樹脂粒子(B)及びマトリックス樹脂(C)を含む混合物[又は樹脂粒子(B)を含むマトリックス樹脂(C)]が含浸(付着)した形態であってもよい。このような形態は、強化繊維(A)及び樹脂粒子(B)が、マトリックス樹脂(C)中に分散した形態ということもできる。
このような組成物は、半結晶性熱可塑性樹脂とこの樹脂に非相溶な水性媒体とを溶融混練した後、得られた溶融混練物から親水性溶媒で前記水性媒体を除去して樹脂粒子(B)を得る樹脂粒子製造工程、強化繊維(A)に、得られた樹脂粒子(B)及びマトリックス樹脂(C)を含浸させる含浸工程を経て得られる。
本発明には、前記組成物の成形品(前記組成物で形成された成形品)も含まれる。このような成形品は、強化繊維(A)と、この強化繊維(A)を分散させるマトリックス樹脂(C)とを含んでいるため、複合材料[繊維強化複合材料(特に炭素繊維複合材料)]ということもできる。
脂環族PA:脂環族ポリアミド、ダイセル・エボニック(株)製「トロガミドCX7323」、融点247℃
1000mLの耐圧ガラスオートクレーブの中に、脂環族ポリアミド(ダイセル・エボニック(株)製「トロガミドCX7323」)18g、ポリビニルアルコール(日本合成化学工業(株)製「ゴーセノールGM-14」)32g、有機溶媒としてN-メチル-2-ピロリドン300gを加え、99体積%以上の窒素置換を行った後、180℃に加熱し、ポリマーが溶解するまで4時間攪拌を行った。その後、送液ポンプを経由して、3g/分のスピードで貧溶媒として350gのイオン交換水を滴下した。約200gのイオン交換水を加えた時点で、系が白色に変化した。全量の水を入れ終わった後、攪拌したまま温度を下げ、得られた懸濁液を濾過し、イオン交換水700gを加えてスラリー洗浄し、濾別した濾過物を80℃で10時間真空乾燥し、約17gの白色固体を得た。
PA12粒子:化学粉砕法で得られたポリアミド12粒子、ダイセル・エボニック(株)製「ベストジント2158」
PA1010:ポリアミド1010、ダイセル・エボニック(株)製「ベスタミド テラBS1393」
非晶性PA:芳香族ポリアミド、ダイセル・エボニック(株)製「トロガミドT5000」
マトリックス樹脂:エポキシ樹脂(三菱化学(株)製、「jER828」)とアミン系硬化剤(三菱化学(株)製、「jERキュアW」)との混合物
炭素繊維:HONLU TECHNOLOGY CO.LTD製「TC-33」、平均繊維径約7μm。
得られた樹脂粒子を水に分散し、レーザー回折/散乱式粒子径分布測定装置((株)堀場製作所製「LA920」)を用いて測定した。
得られた樹脂粒子について、示差走査熱量計(SII(株)製「X-DSC7000」)を用いて、室温から300℃まで10℃/分で昇温し、その間(ガラス転移温度と融点との間)に結晶化のピークが観測できるか否かを確認した。
全自動・試料水平型多目的X線回折測定装置((株)リガク製「SmartLab」)を用いて、水平円卓型試料台上の中央部に、得られた樹脂粒子を置き、パッケージ測定プログラム「汎用(集中法)」を実行して、以下の測定条件で集中法によるX線回折パターンを測定した。
1次X線源:Cuを対陰極とする回転対陰極型線源(加速電圧-電流:45kV-200mA)
走査ステップ:0.02°
走査速度:4°/min(2θ)。
粉末X線解析ソフトウェア((株)リガク製「PDXL Ver2.3.1.0」)を用いて、広角X線回折で得られた回折曲線にフィッティング(方法:FP法、ピーク形状:対数正規分布、バックグラウンド精密化:なし)を行うことにより結晶回折ピーク、非晶質ハロを分離し、以下の式から結晶化度(%)を求めた。
得られた試験片Aについて、JIS K7086-1993に準拠して、き裂進展初期のモードI層間破壊靱性値(GIC)を測定した。
得られた試験片Bについて、ISO179/1eAに準拠して、試験温度23℃でシャルピー衝撃強度を測定した。
(樹脂粒子の製造)
ポリエチレングリコールを用いて、特開2010-132811号公報の実施例に準じ、強制乳化法で脂環族PAを微粒子化した。押出機のダイから押し出された溶融混練物に対して、スポットクーラーを用いて強制的に冷却した後、水洗によりポリエチレングリコールのみを除き、温度120℃で減圧乾燥により24時間乾燥させ樹脂粒子(パウダー)を得た。樹脂粒子の平均粒径は21μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測された。DSCによるチャート(吸音曲線)を図1に示す。図1から明らかなように、170℃前後で結晶化による大きなピークを確認でき、結晶化度も低いため、得られた粒子が低結晶性であることが確認できる。
マトリックス樹脂に対して、5重量%で樹脂粒子を添加し、ホットスターラーを用いて、100℃、600rpmの条件で24時間攪拌した。その後、さらに、真空容器中で1時間放置することで脱泡し、樹脂粒子を含むマトリックス樹脂を得た。
マトリックス樹脂に対して、20重量%で樹脂粒子を添加し、ISO179/1eAに準拠した形状の試験Bを製造した。
樹脂粒子として、化学粉砕法で得られた脂環族PA粒子を用いて、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は23μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測されなかった。DSCによるチャート(吸音曲線)を図2に示す。図2から明らかなように、170℃前後で結晶化によるピークは確認できず、得られた粒子が高結晶性であることが確認できた。
樹脂粒子の製造において、スポットクーラーを使用せずに溶融混練物を自然放冷し、ポリエチレングリコールを除去後に、減圧乾燥せずに180℃で3時間加熱して乾燥する以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は23μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測されず、結晶化度も高かった。
樹脂粒子の製造において、脂環族PA及びポリエチレングリコールの代わりに、PA12及び糖を用いて、スポットクーラーを使用せずに溶融混練物を自然放冷し、糖を除去後に、減圧乾燥せずに80℃で3時間加熱して乾燥する以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は20μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測された。DSCによるチャート(吸音曲線)を図4に示す。図4から明らかなように、170℃前後で結晶化によるピークを確認できた。また、広角X線のチャートを図5に示す。図5から明らかなように、得られたPA12粒子は、2θ=21.5°に1つのピークを有するγ型結晶構造であることを確認できた。
樹脂粒子として、化学粉砕法で得られたPA12粒子を用いて、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は24μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測されなかった。DSCによるチャート(吸音曲線)を図6に示す。図6から明らかなように、170℃前後で結晶化によるピークは確認できなかった。また、広角X線のチャートを図7に示す。図7から明らかなように、比較例3で得られたPA12粒子は、2θ=20.6°及び2θ=22.3°に2つのピークを有するα型結晶構造であることを確認できた。
樹脂粒子の製造において、脂環族PA及びポリエチレングリコールの代わりに、PA1010及び糖を用いて、スポットクーラーを使用せずに溶融混練物を自然放冷し、糖を除去後に、減圧乾燥せずに80℃で3時間加熱して乾燥する以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は22μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測された。また、広角X線のチャートを図8に示す。図8から明らかなように、実施例3で得られたPA1010粒子は、2θ=20.4°及び2θ=23.6°に2つのピークを有するα型結晶構造であることを確認できた。
化学粉砕法でPA1010を微粒子化した。得られた微粒子を用いて実施例1と同様の方法で試験片を作製した。樹脂粒子の平均粒径は18μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測されなかった。また、広角X線のチャートを図9に示す。図9から明らかなように、比較例4で得られたPA1010粒子は、2θ=20.0°及び2θ=24.1°に2つのピークを有するα型結晶構造であることを確認できたが、結晶化度は実施例3で得られたPA1010粒子よりも高かった。
樹脂粒子の製造において、ポリエチレングリコールの代わりに、ポリビニルアルコールを用いる以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は11μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測された。
樹脂粒子の製造において、脂環族PA及びポリエチレングリコールの代わりに、PA12及び糖を用いて、スポットクーラーを使用せずに溶融混練物を自然放冷し、糖を除去後に、減圧乾燥せずに80℃で3時間加熱して乾燥する以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は5μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測された。
樹脂粒子の製造において、脂環族PAの代わりに、非晶性PAを用いて、ポリエチレングリコール除去後に、減圧乾燥により140℃で24時間乾燥する以外は、実施例1と同様にして試験片を作製した。樹脂粒子の平均粒径は19μmであり、DSCによる10℃/分の昇温条件で結晶化のピークが観測されなかった。
樹脂粒子を使用せずに試験片を製造した。
Claims (12)
- 強化繊維(A)、樹脂粒子(B)及びマトリックス樹脂(C)を含む樹脂組成物であって、
前記強化繊維(A)が炭素繊維を含み、
前記樹脂粒子(B)が、半結晶性熱可塑性樹脂を含み、示差走査熱量測定(DSC)によって10℃/分の速度で昇温したとき、前記半結晶性熱可塑性樹脂のガラス転移温度と融点との間の温度範囲に発熱ピークを有し、かつ平均粒径3~40μmを有する樹脂組成物。 - 半結晶性熱可塑性樹脂が、融点150℃以上のポリアミド樹脂である請求項1記載の樹脂組成物。
- ポリアミド樹脂が、脂環式構造を有し、かつガラス転移温度が100℃以上である請求項2記載の樹脂組成物。
- 半結晶性熱可塑性樹脂が、γ型結晶構造又は50%以下の結晶化度を有するポリアミド樹脂である請求項1記載の樹脂組成物。
- ポリアミド樹脂が、脂肪族ポリアミド樹脂である請求項4記載の樹脂組成物。
- 樹脂粒子(B)が衝撃性改良剤をさらに含む請求項1~5のいずれかに記載の樹脂組成物。
- マトリックス樹脂(C)が熱硬化性樹脂である請求項1~6のいずれかに記載の樹脂組成物。
- 樹脂粒子(B)が、球状であり、かつ平均粒径15~25μmを有する請求項1~7のいずれかに記載の樹脂組成物。
- 半結晶性熱可塑性樹脂とこの樹脂に非相溶な水性媒体とを溶融混練した後、得られた溶融混練物から親水性溶媒で前記水性媒体を除去して樹脂粒子(B)を得る樹脂粒子製造工程と、強化繊維(A)に、得られた樹脂粒子(B)及びマトリックス樹脂(C)を含浸させる含浸工程とを含む請求項1~8のいずれかに記載の樹脂組成物の製造方法。
- 樹脂粒子製造工程において、水性媒体を除去後、半結晶性熱可塑性樹脂のガラス転移温度をTgとするとき、(Tg+40)℃以下の温度で乾燥する請求項9記載の製造方法。
- 請求項1~8のいずれかに記載の樹脂組成物を含む成形品。
- 炭素繊維を含む強化繊維(A)及びマトリックス樹脂(C)を含む組成物に添加し、前記強化繊維(A)の補強効果を向上又は改善するための添加剤であって、半結晶性熱可塑性樹脂を含み、示差走査熱量測定(DSC)によって10℃/分の速度で昇温したとき、前記半結晶性熱可塑性樹脂のガラス転移温度と融点との間の温度範囲に発熱ピークを有し、かつ平均粒径3~40μmを有する樹脂粒子(B)を含む添加剤。
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KR102178286B1 (ko) * | 2020-06-11 | 2020-11-13 | 주식회사 대명테크 | 롤투롤 공정을 이용한 탄소섬유강화플라스틱의 제조방법 및 상기 제조방법으로 제조된 적층형 탄소섬유강화플라스틱 |
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