WO2021246532A1 - ポリイミド樹脂成形体及びその製造方法 - Google Patents
ポリイミド樹脂成形体及びその製造方法 Download PDFInfo
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- WO2021246532A1 WO2021246532A1 PCT/JP2021/021473 JP2021021473W WO2021246532A1 WO 2021246532 A1 WO2021246532 A1 WO 2021246532A1 JP 2021021473 W JP2021021473 W JP 2021021473W WO 2021246532 A1 WO2021246532 A1 WO 2021246532A1
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- polyimide resin
- addition reaction
- type polyimide
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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
- C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
- C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
- C08G73/10—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F299/00—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers
- C08F299/02—Macromolecular compounds obtained by interreacting polymers involving only carbon-to-carbon unsaturated bond reactions, in the absence of non-macromolecular monomers from unsaturated polycondensates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/006—Pressing and sintering powders, granules or fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/34—Feeding the material to the mould or the compression means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/52—Heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
-
- 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
- C08G2/00—Addition polymers of aldehydes or cyclic oligomers thereof or of ketones; Addition copolymers thereof with less than 50 molar percent of other substances
- C08G2/30—Chemical modification by after-treatment
- C08G2/34—Chemical modification by after-treatment by etherification
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/5816—Measuring, controlling or regulating temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/5875—Measuring, controlling or regulating the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
- B29K2079/08—PI, i.e. polyimides or 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
- C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
- C08J2379/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08J2379/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
-
- 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
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
Definitions
- the present invention relates to a polyimide resin molded product and a method for producing the same, and more particularly to a thick polyimide resin molded product having no surface defects or internal voids and a method for producing the same.
- the addition reaction type polyimide resin composed of an aromatic polyimide oligomer having an addition reaction group at the terminal has a low melt viscosity and excellent impregnation property into fibers, and is well formed by transfer molding (RTM) or resin press-fitting (RI). Since it is possible, it is widely used as a matrix for carbon fiber reinforced composites. Since the composite constituent materials obtained by these methods have excellent properties such as heat resistance, weather resistance, mechanical strength, and durability, they are used for transportation equipment such as automobiles and aircraft, civil engineering / construction materials, sports equipment, etc. Widely used in applications. It is used in the aerospace field, etc. (Patent Document 1 etc.).
- the above-mentioned addition reaction type polyimide resin is generally used as a matrix of carbon fiber reinforced composite by blending functional fibers such as carbon fibers, but is a neat resin molded product containing no carbon fibers or the like.
- the demand for thick neat resin molded products having a thickness of 5 mm or more is particularly high.
- Patent Document 1 relating to an addition reaction type polyimide resin
- a neat resin molded product having a diameter of 1.5 inches and a thickness of 25 mm can be molded by using an addition reaction type polyimide resin and heating it at 350 to 371 ° C. for 1 hour.
- the neat resin molded product described in Patent Document 1 is an extremely thin molded product having a thickness of about 0.6 mm.
- the viscosity in the mold is not uniform and the viscosity in the mold is not uniform, and the prepolymer is not uniform at all positions in the mold. Since the viscosity cannot be adjusted to be suitable for molding, resin leakage, air bubbles, expansion, etc. occur, and it is not possible to mold a thick molded product without defects.
- an object of the present invention is to provide a molded product made of a thick addition-reaction polyimide resin having a thickness of 5 mm or more, in which surface defects such as voids and cracks are significantly reduced, and a method for producing the same.
- Another object of the present invention is a molded product made of an addition reaction type polyimide resin having excellent mechanical strength in which the generation of internal voids is effectively prevented even in a thick molded product having a thickness of 15 mm or more, and a molded product thereof. It is to provide a manufacturing method.
- Still another object of the present invention is to provide a molding precursor capable of molding an addition reaction type polyimide resin molded product having a thickness of 5 mm or more.
- the present invention is an addition reaction type polyimide resin molded body having a thickness of 5 mm or more, and the number of defects of 0.5 mm or more existing on the surface of the molded body is 1 piece / 100 cm 2 or less.
- the first addition reaction type polyimide resin molded article is provided.
- a second addition reaction type polyimide resin molded body having a thickness of 15 mm or more and having a bending strength of 60 MPa or more. ..
- the defect in the first addition reaction type polyimide resin molded product is a recess or a bubble having a maximum diameter of 0.5 mm or more, or a crack having a length of 0.5 mm or more.
- the first addition reaction type polyimide resin molded product also has a thickness of 15 mm or more and a bending strength of 60 MPa or more.
- the addition reaction type polyimide resin is a polyimide resin having a phenylethynyl group as an addition reaction group.
- the shape of the molded body is a disk-shaped or rectangular flat plate with a thickness of 5 to 30 mm. 5. When heated at a temperature of 357 ° C. for 6 hours, no deformation occurs, or convex deformation with a height of less than 1 mm occurs. Is preferable.
- the prepolymer of the addition reaction type polyimide resin is held at a temperature equal to or higher than the thickening start temperature of the addition reaction type polyimide resin, and the melt viscosity under a temperature condition 10 ° C. lower than the thickening start temperature is 70.
- a method for producing an addition reaction type polyimide resin molded body which comprises a shaping step of shaping at a temperature equal to or higher than the thermosetting temperature.
- the molding is further made of an addition reaction type polyimide resin, and has a melt viscosity of 70 to 900 kPa ⁇ s under a temperature condition 10 ° C. lower than the thickening start temperature of the addition reaction type polyimide resin.
- a precursor is provided.
- the bending strength and the thickening start temperature are defined as follows.
- the thickness direction of the molded body is the thickness of the test piece (length 50 mm x width 10 mm x thickness 3 mm). 3 mm downward from the upper surface of the molded body in the thickness direction, 3 mm with the thickness (t) center (position of t / 2) of the molded body as the center of thickness (neutral surface), and 3 mm upward in the thickness direction from the lower surface of the molded body.
- a test piece having a thickness of 50 mm in length and 10 mm in width at each position is cut out.
- a bending test is performed using this test piece, and the smallest value of the bending stress of each obtained test piece is taken as the bending strength of the molded product. The measurement conditions will be described later.
- the resin molded product of the present invention is a resin molded product having a thickness of 5 mm or more and made of an addition reaction type polyimide resin having excellent heat resistance, durability and mechanical strength, and has a surface defect having a size of 0.5 mm or more. Can be provided as a thick molded product in which the amount of heat is significantly reduced.
- the surface defects are not limited to these, but bubbles formed on the surface due to air contained in the resin, gas generated from the resin, and the like, and these bubbles are included. It means concave defects (also called voids or depressions) or cracks that occur on the surface due to crushing or deformation during compression.
- the resin molded product of the present invention has a bending strength of 60 MPa or more and has excellent mechanical strength because no void is formed inside the molded product even when the resin molded product has a thickness of 15 mm or more. ing. Further, according to the method for producing a resin molded product of the present invention, the viscosity is adjusted in advance under a temperature condition 15 to 45 ° C. higher than the thickening start temperature of the addition reaction type polyimide resin, and this is pulverized and mixed to form a shape.
- the molding precursor of the present invention is uniformly adjusted to a suitable melt viscosity at the molding temperature to the resin molded body, it is not necessary to adjust the viscosity immediately before shaping, and the molding precursor is heated immediately before shaping. Unlike the case where the viscosity is adjusted, there is no risk of bubble generation and crushing, and a thick resin molded body without surface defects and internal voids can be efficiently molded.
- the resin molded product has a thickness of 5 mm or more, and surface defects of 0.5 mm or more are reduced to 1 piece / 100 cm 2 or less.
- the shape of the resin molded product in the present invention does not matter as long as it has a thickness of 5 mm or more, particularly a thickness of 5 to 30 mm. Specifically, as is clear from the molding method of the resin molded body of the present invention described later, the shape is not particularly limited as long as it can be molded by compression molding or transfer molding.
- the thickness means the maximum thickness in the obtained molded body, but in the case of compression molding or transfer molding, the moving direction of the molding die is the thickness direction of the resin molded body.
- Suitable shapes for the resin molded body of the present invention include flat plates such as discs and squares, cylinders, prisms, etc., as well as shapes having curved surfaces and moldings of the above-mentioned shapes such as discs as shown in FIG.
- An example may be a resin molded body in which a plurality of bodies are formed.
- the resin molded product of the present invention has no defects of 0.5 mm or more, particularly defects in the range of 0.5 to 50 mm, that is, zero as much as possible, even if there are defects.
- the defects are reduced to 1 piece / 100 cm 2 or less on the entire surface of the molded body.
- the above-mentioned defects are not limited to this, but are concave defects and bubbles having a maximum diameter of 0.5 mm or more, cracks having a maximum length of 0.5 mm or more, and the like, for example, defects as shown in FIG. Can be particularly exemplified.
- the addition reaction type polyimide resin molded product of the present invention does not undergo deformation even when heated at a temperature of 357 ° C. for 6 hours, or even if deformation occurs, convex deformation having a height of less than 1 mm occurs. Yes, it has excellent thermal stability. That is, the resin molded product of the present invention has a uniform melt viscosity of the molding precursor in the molding mold, and is sufficiently and uniformly thermoset in the shaping step as described later, so that an unreacted addition reaction is performed. The prepolymer content of the molded polyimide resin is reduced as much as possible.
- the convex deformation is defined as the difference in the maximum thickness of the addition reaction type polyimide resin molded body before and after heating at a temperature of 357 ° C. for 6 hours.
- a molded product made of an addition reaction type polyimide resin generally tends to have a decrease in mechanical strength because voids are likely to be formed inside the molded product having a thickness of 15 mm or more.
- the resin of the present invention has a tendency to decrease.
- the generation and expansion of bubbles are reduced, so that the formation of voids inside the molded body is suppressed even in a thick molded body having a thickness of 15 mm or more.
- the bending strength is as large as 60 MPa or more, and it has excellent mechanical strength.
- the second addition reaction type polyimide resin molded product of the present invention is a thick molded product having a thickness of 15 mm or more, it is possible to remove surface defects by a treatment such as polishing the surface, and it is not always the first. As specified for one addition reaction type polyimide resin molded product, surface defects may not be significantly reduced.
- the addition reaction type polyimide resin constituting the resin molded product of the present invention is made of an aromatic polyimide oligomer having an addition reaction group at the terminal, and one prepared by a conventionally known production method can be used.
- aromatic tetracarboxylic acid dianhydride, aromatic diamine, and a compound having an anhydride group or an amino group together with an addition reaction group in the molecule, the total of the equivalents of each acid group and the total of each amino group are approximately the same. It can be easily obtained by using it in equal amounts and preferably reacting in a solvent.
- a reaction method a method of polymerizing at a temperature of 100 ° C. or lower, preferably 80 ° C.
- a method consisting of two steps of heating at a high temperature of about 140 to 270 ° C. for thermal imidization, or from one step of carrying out a polymerization / imidization reaction at a high temperature of 140 to 270 ° C. for 0.1 to 50 hours from the beginning.
- the solvent used in these reactions is not limited to this, but is limited to N-methyl-2-pyrrolidone, N, N-dimethylformamide, N, N-dimethylacetamide, N, N-diethylacetamide, ⁇ -butyllactone, N-.
- An organic polar solvent such as methylcaprolactum can be preferably used.
- the addition-reactive group at the terminal of the aromaticimide oligomer is not particularly limited as long as it is a group that undergoes a curing reaction (additional polymerization reaction) by heating when producing a resin molded body, but the curing reaction is preferably performed.
- any reaction group preferably selected from the group consisting of a phenylethynyl group, an acetylene group, a nadic acid group, and a maleimide group.
- the phenylethynyl group is particularly preferable because it does not generate a gas component due to the curing reaction, and the obtained resin molded product has excellent heat resistance and mechanical strength. be.
- a compound having an anhydride group or an amino group together with the addition reaction group in the molecule preferably forms an imide ring with the amino group or the acid anhydride group at the terminal of the aromatic imide oligomer. Is introduced at the end of the aromatic imide oligomer.
- Compounds having an anhydride group or an amino group together with an addition reaction group in the molecule include, for example, 4- (2-phenylethynyl) phthalic anhydride, 4- (2-phenylethynyl) aniline, 4-ethynyl-phthalic anhydride, 4 -Ethynylaniline, nadic acid anhydride, maleic acid anhydride and the like can be preferably used.
- Examples of the tetracarboxylic acid component forming the aromatic imide oligomer having an addition reactive group at the terminal include 2,3,3', 4'-biphenyltetracarboxylic acid dianhydride, 2,2', 3,3'-biphenyl. At least selected from the group consisting of tetracarboxylic acid dianhydride, 3,3', 4,4'-biphenyltetracarboxylic acid dianhydride, and 3,3', 4,4'-benzophenone tetracarboxylic acid dianhydride.
- One tetracarboxylic acid dianhydride can be exemplified, and in particular, 2,3,3', 4'-biphenyltetracarboxylic acid dianhydride can be preferably used.
- the diamine component forming an aromatic imide oligomer having an addition reactive group at the terminal is not limited to this, but is limited to 1,4-diaminobenzene, 1,3-diaminobenzene, 1,2-diaminobenzene, and 2,6-.
- a mixed diamine composed of at least two aromatic diamines selected from the group consisting of methyl) benzidine, in particular 1,3-diaminobenzene and 1,3-bis (4-aminophenoxy) benzene.
- Mixed diamine consisting of a combination of 3,4'-diaminodiphenyl ether and 4,4'-diaminodiphenyl ether, mixed diamine consisting of a combination of 3,4'-diaminodiphenyl ether and 1,3-bis (4-aminophenoxy).
- a mixed diamine consisting of a combination with benzene a mixed diamine consisting of a combination of 4,4'-diaminodiphenyl ether and 1,3-bis (4-aminophenoxy) benzene, and a 2,2'-bis (trifluoromethyl) benzidine. It is preferable to use a mixed diamine composed of a combination of 1,3-bis (4-aminophenoxy) benzene from the viewpoint of heat resistance and moldability.
- the aromatic imide oligomer having an addition reaction group at the terminal used in the present invention preferably has a repeating unit of the imide oligomer of 0 to 20, particularly 1 to 5, and has a number average molecular weight in terms of styrene by GPC. However, it is preferably 10,000 or less, particularly 3000 or less. When the number of repetitions of the repetition unit is in the above range, the melt viscosity is adjusted to an appropriate range, and it becomes possible to mix the functional fibers. Further, it is not necessary to mold at a high temperature, and it is possible to provide a resin molded product having excellent moldability, heat resistance, and mechanical strength.
- the number of repetitions of the repetition unit can be adjusted by changing the proportion of the aromatic tetracarboxylic acid dianhydride, the aromatic diamine, and the compound having an anhydride group or an amino group together with the addition reaction group in the molecule.
- the proportion of the compound having an anhydride group or an amino group together with the addition reaction group in the molecule By increasing the proportion of the compound having an anhydride group or an amino group together with the addition reaction group in the molecule, the molecular weight is reduced and the number of repetitions of the repeating unit is reduced, and when the proportion of this compound is decreased, the molecular weight is increased and the repetition is repeated.
- the number of repetitions of the unit increases.
- resin additives such as flame retardants, colorants, lubricants, heat stabilizers, light stabilizers, ultraviolet absorbers, fillers, etc. are known depending on the intended use of the resin molded body. It may be formulated according to the formulation.
- the prepolymer of the addition reaction type polyimide resin is held at a temperature equal to or higher than the thickening start temperature of the addition reaction type polyimide resin, and under a temperature condition 10 ° C. lower than the thickening start temperature.
- the addition reaction type polyimide resin used for producing the resin molded body of the present invention has a low viscosity in the state of the prepolymer before cross-linking and curing, the prepolymer supplied to the molding die in the shaping step of the resin molded body.
- the polymer is thickened, there is a problem that the viscosity increase is small near the center of the molding die, the viscosity increase is large near the molding die, and the viscosity of the prepolymer is not uniform.
- the viscosity When the viscosity is adjusted based on the central part of the molding mold, the prepolymer near the vessel wall of the molding mold is thermally decomposed to foam and expand, and the subsequent pressurization by compression molding causes the bubbles to collapse and voids to be generated. Occurs. On the other hand, if the viscosity of the prepolymer near the wall of the mold is used as a reference, the viscosity is too low to be molded, and there arises a problem that the molten resin leaks from the mold.
- the melt viscosity of the prepolymer is increased to 70 to 900 kPa ⁇ s under the temperature condition 10 ° C. lower than the thickening start temperature by the thickening step, and then the melt viscosity is performed.
- the addition reaction type polyimide resin whose melt viscosity is adjusted to the above range is powdered and mixed to prepare a powdery molding precursor having a uniform melt viscosity. This eliminates the need for thickening in the shaping process, and as a result, as described above, there are no defects of 0.5 mm or more, or even if there are, surface defects of 1 piece / 100 cm 2 or less are significantly reduced. It becomes possible to mold a resin molded body having a thickness of 5 mm or more.
- the prepolymer (imide oligomer) of the addition reaction type polyimide resin is first melted by holding it at a temperature equal to or higher than the thickening start temperature of the addition reaction type polyimide resin for a certain period of time using an electric furnace or the like.
- the viscosity is increased to 70 to 900 kPa ⁇ s, preferably 10 ° C. lower than the thickening start temperature by holding for 50 to 200 minutes, particularly 65 to 110 minutes in a temperature range 15 to 45 ° C. higher than the thickening start temperature.
- the melt viscosity of the prepolymer is increased to 70-900 kPa ⁇ s.
- the thickening step is performed at a temperature equal to or higher than the thickening start temperature of the prepolymer and lower than a temperature at which the prepolymer is completely crosslinked and cured.
- the reaction start temperature depends on the addition reaction group, and in the polyimide resin having a phenylethynyl group suitable as an addition reaction group in the present invention, it is 320 ⁇ 15 near the thickening start temperature. It is desirable to increase the melt viscosity to 70 to 900 kPa ⁇ s by holding at a temperature of ° C. for a certain period of time.
- the lump of the addition reaction type polyimide resin obtained by cooling (including allowing to cool) and solidifying after passing through the thickening step can be stored over time and is excellent in handleability, but the position of the lump, for example, the lump There is a difference in viscosity between the surface and the central part of the mass. Therefore, it is preferable that the molding precursor of the present invention is powdered and mixed by a pulverizing and mixing step described later.
- the mass of the addition reaction type polyimide resin whose melt viscosity is adjusted to 70 to 900 kPa ⁇ s under the temperature condition 10 ° C. lower than the thickening start temperature obtained through the thickening step has a viscosity depending on the position of the mass.
- this is pulverized and mixed to obtain a powdery molding precursor.
- a conventionally known pulverizing mixer such as a Henschel mixer, a tumbler mixer, a ribbon blender, a jet mill, a roller mill, a ball mill, a spike mill, or a vibration mill can be used, but pulverizing and mixing are efficiently performed at the same time. It is particularly preferable to use a Henschel mixer because it can be used.
- the particle size of the powdery molding precursor is preferably in the range of 1 to 1000 ⁇ m in the average particle size (D50) measured by the laser scattering diffraction method.
- the molding precursor of the present invention has a melt viscosity of 70 to 900 kPa ⁇ s under a temperature condition 10 ° C. lower than the thickening start temperature of the addition reaction type polyimide resin.
- a predetermined temperature is set in the molding mold at a temperature equal to or higher than the melting temperature and lower than the thickening start temperature. It is also possible to provide a preheating step of holding for 10 to 30 minutes at a temperature 5 to 20 ° C. lower than the thickening start temperature, preferably 5 to 20 ° C.
- the powdery molding precursor introduced into the molding die or the molding precursor in a state of being slightly melted through the preheating step in the molding die is under a temperature condition equal to or higher than the thermosetting temperature of the addition reaction type polyimide resin to be used.
- a polyimide resin having a phenylethynyl group as an addition reaction group it is molded as a desired resin molded product by shaping at a temperature of 360 to 390 ° C.
- the powdery molded precursor of the present invention has a uniform melt viscosity as a molded precursor because it is pulverized and mixed.
- the resin has a thickness of 5 mm or more, particularly 5 to 30 mm. , 0.5 mm or more defects are not generated, or even if they are generated, a resin molded body without defects of 1 piece / 100 cm 2 or less can be molded.
- the shaping is preferably by compression molding or transfer molding in which the mixture introduced into the molding die is pressure-compressed and molded. It may be molded by molding or extrusion molding.
- the thickening start temperature of the addition reaction type polyimide resin used was measured with a rheometer.
- the melting viscosity was measured with a parallel plate at an angular frequency of 100 rad / s and a strain of 10% under temperature conditions where the reaching speed to the target temperature was 4 ° C./min and held for 120 minutes after reaching the target reaching temperature, and the minimum melting was performed.
- the time showing the viscosity is set to 0 minutes, the horizontal axis is the time (min), and the vertical axis is the melt viscosity (Pa ⁇ s).
- the B value is 0.0092 when the target temperature is 285 ° C, and the B value is 0.0141 when the target temperature is 290 ° C.
- the starting temperature was 290 ° C.
- melt viscosity of the addition reaction type polyimide resin used at a temperature 10 ° C. lower than the thickening start temperature was measured by a rheometer (ARES-G2 manufactured by TA instrument). Using a parallel plate, the strain was 1% (measurement gap was 1 mm), the angular frequency range was 0.1 to 100 rad / s, and the melt viscosity at 0.1 rad / s when the melt viscosity was measured was used as the measured value. ..
- the powdery molding precursor was heated and pressed at a temperature 10 ° C. to 40 ° C. lower than the thickening start temperature by a hot press to form a smooth plate.
- test piece (length 50 mm x width 10 mm x thickness) cut out from a resin molded product using an autograph (AG-1 / 50N-10 kN manufactured by Shimadzu Corporation) in accordance with JIS K 7171 (plastic-test method for bending characteristics). A bending test was performed at a test speed of 1 mm / min for 3 mm), and the bending strength was measured. The test piece was cut out at a position of 3 mm from the upper surface of the resin molded body in the thickness direction, ⁇ 1.5 mm from the neutral surface, and 3 mm from the lower surface of the molded body.
- the maximum thickness of the addition reaction type polyimide resin molded body before and after heating at a temperature of 357 ° C. for 6 hours was measured with a measuring instrument such as a caliper or a height gauge. If the thickness difference is less than 1 mm, it is evaluated as good ( ⁇ ), and if it is 1 mm or more, it is evaluated as (x).
- Example 1 The addition reaction type polyimide (PETI-330 manufactured by Ube Industries, Ltd.) is held at a resin temperature of 330 ° C. for 65 minutes in an electric furnace, and the melt viscosity is 280 ° C. lower than the thickening start temperature of the addition reaction type polyimide. The melt viscosity at ° C was adjusted to 126.6 kPa ⁇ s. Then, it was rapidly cooled to obtain a mass of an addition reaction type polyimide resin cooled to room temperature. The obtained resin mass is crushed and mixed with a pulverizing mixer, supplied to a compression molding mold, preheated at 280 ° C.
- PETI-330 manufactured by Ube Industries, Ltd.
- Example 2 The resin temperature in the electric furnace was changed to 330 ° C. and the holding time was changed to 95 minutes, and the melt viscosity was adjusted to 642.9 kPa ⁇ s at 280 ° C, which is 10 ° C lower than the thickening start temperature of the addition reaction type polyimide. It was the same as in Example 1 except that.
- Example 1 (Examples 3, 5, 7, 9, 11) The same was applied to Example 1 except that the thickness of the molded product was the thickness shown in Table 1.
- Example 4 It was the same as in Example 2 except that the thickness of the molded product was the thickness shown in Table 1.
- Example 13 The same as in Example 11 except that the resin temperature in the electric furnace was changed to 330 ° C. and the holding time was changed to 110 minutes to adjust the viscosity. Since the melt viscosity of the addition reaction type polyimide resin whose viscosity was adjusted at 280 ° C., which is 10 ° C. lower than the thickening start temperature, could not be measured, the thickening step was reproduced in the rheometer. The temperature was raised from 280 ° C. to 3.1 ° C./min in a rheometer, and the time when the temperature reached 330 ° C.
- Example 14 The resin temperature in the electric furnace was changed to 330 ° C., the holding time was changed to 120 minutes, and the viscosity was adjusted in the same manner as in Example 11. Since the melt viscosity of the addition reaction type polyimide resin whose viscosity was adjusted at 280 ° C., which is 10 ° C. lower than the thickening start temperature, could not be measured, the thickening step was reproduced in the rheometer. The temperature was raised from 280 ° C. to 3.1 ° C./min in a rheometer, and the time when the temperature reached 330 ° C.
- Comparative Example 2 It was the same as in Comparative Example 1 except that the thickness of the molded product was 5 mm.
- Comparative Examples 3 to 7 The same as in Comparative Example 1 except that the mold temperature was changed to 320 ° C. and the holding time was changed to 40 minutes, and the thickness of the molded product was set to the thickness shown in Table 2.
- FIG. 2A shows a compressed surface
- FIG. 2B shows a side surface
- FIG. 3 (A) An enlarged photograph of the side surface of the molded product obtained in Comparative Example 7 is shown in FIG.
- FIG. 5A shows a compressed surface
- FIG. 5B shows a side surface.
- FIG. 5 there was a portion that was deformed in a convex shape.
- FIGS. 6 and 7 show cross sections in the thickness direction of the molded products obtained in Comparative Examples 5 and 7, respectively.
- Comparative Example 5 which is a molded product of 15 mm
- a plurality of internal voids were partially formed.
- FIG. 7 in Comparative Example 7, which is a molded product having a thickness of 30 mm, a large number of internal voids were present as a whole.
- the resin molded product of the present invention is a thick molded product having a thickness of 5 mm or more, surface defects are remarkably reduced, and the generation of voids inside the resin molded product is suppressed, resulting in heat resistance. It has excellent durability and mechanical strength, and can be used for various purposes as a member in the fields of automobiles, electric and electronic fields, and the like.
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Abstract
Description
本発明の他の目的は、15mm以上の厚みを有する厚物の成形体であっても内部ボイドの発生が有効に防止された機械的強度に優れた付加反応型ポリイミド樹脂から成る成形体及びその製造方法を提供することである。
本発明の更に他の目的は、5mm以上の厚みを有する付加反応型ポリイミド樹脂成形体を成形可能な成形前駆体を提供することである。
本発明によればまた、15mm以上の厚みを有する付加反応型ポリイミド樹脂成形体であって、曲げ強度が60MPa以上であることを特徴とする第二の付加反応型ポリイミド樹脂成形体が提供される。
1.第一の付加反応型ポリイミド樹脂成形体における前記欠陥が、最大直径が0.5mm以上の凹部又は気泡、或いは長さ0.5mm以上の亀裂であること、
2.第一の付加反応型ポリイミド樹脂成形体においても、厚みが15mm以上であり、曲げ強度が60MPa以上であること、
3.前記付加反応型ポリイミド樹脂が、付加反応基としてフェニルエチニル基を有するポリイミド樹脂であること、
4.成形体の形状が、厚みが5~30mmのディスク状又は矩形状の平板状であること、
5.温度357℃で6時間加熱した場合に、変形を生じないか、或いは高さが1mm未満の凸状変形を生じること、
が好適である。
1.前記増粘工程において、前記付加反応型ポリイミド樹脂を増粘開始温度より15~45℃高い温度範囲で50~200分間保持すること、
2.前記賦形工程が、圧縮成形により行われること、
が好適である。
(1)曲げ強度
JIS K 7171(プラスチック-曲げ特性の試験方法)に準拠し、成形体の厚み方向(成形型の移動方向)を試験片(長さ50mm×幅10mm×厚み3mm)の厚さとし、成形体の上面から厚み方向下方に3mm、成形体の厚み(t)中心(t/2の位置)を厚み中心(中立面)として3mm、成形体の下面から厚み方向上方に3mm、の各位置における厚みを有する長さ50mm×幅10mmの試験片を切り出す。この試験片を用いて曲げ試験を行い、得られた各試験片の曲げ応力の最も小さい値を、成形体の曲げ強度とする。測定条件は後述する。
レオメータでパラレルプレートを用い、角周波数100rad/sにおいて、4℃/minで昇温し、所定の目標温度に到達後、その目標温度で一定時間保持する条件下で、未反応状態の付加反応型ポリイミド樹脂の粘度を測定する。昇温することによって溶融し、粘度が低下する。測定中に最も低い粘度を最低溶融粘度とし、目標温度到達後120分経過するまでの溶融粘度を求める。目標温度を5の倍数の温度で低い温度から高い温度に向かって設定してそれぞれ溶融粘度の計測を行う。最低溶融粘度を示す時間を0分とし、横軸を時間(min)、縦軸を溶融粘度(Pa・s)とした片対数グラフにプロットし、表計算ソフトにより指数近似式を求める。下記式(1)に示される近似式のBの値がはじめて0.014を超える温度を増粘開始温度とする。
Y=Aexp(Bx) ・・・(1)
式中、Y:溶融粘度(Pa・s)、x:時間(min)、A及びB:定数
また本発明の樹脂成形体は、15mm以上の厚みを有する場合でも、成形体内部にボイドが形成されていないことから、60MPa以上の曲げ強度を有しており、優れた機械的強度を有している。
更に本発明の樹脂成形体の製造方法によれば、付加反応型ポリイミド樹脂の増粘開始温度から15~45℃高い温度条件で予め粘度調整し、これを粉砕混合しておくことにより、賦形に際して成形型内での場所による粘度の差が生じることを有効に防止でき、5mm以上、特に5~30mmの厚みを有する成形体を、ボイドや亀裂等の欠陥を生じることなく、成形することができる。
更にまた本発明の成形前駆体は、樹脂成形体への成形温度における好適な溶融粘度に均一に調整されていることから、賦形直前の粘度調整が不要であり、賦形直前に加熱して粘度調整した場合のように気泡の発生及び圧潰のおそれがなく、表面欠陥及び内部ボイドのない厚物の樹脂成形体を効率よく成形することができる。
前述した通り、付加反応型ポリイミド樹脂から成るニート樹脂成形体においては、成形体表面に欠陥を生じることなく5mm以上の厚みを有する樹脂成形体を成形することが困難であったが、本発明の樹脂成形体は、5mm以上の厚みを有すると共に、0.5mm以上の表面欠陥が1個/100cm2以下と低減されている。
本発明における樹脂成形体は、5mm以上の厚み、特に5~30mmの厚みを有する限りその形状は問わない。具体的には、後述する本発明の樹脂成形体の成形方法から明らかなように、圧縮成形、トランスファー成形により成形できる形状であれば特に限定されない。また厚みは、得られる成形体における最大厚みを意味するが、圧縮成形やトランスファー成形による場合には、成形型の移動方向が樹脂成形体の厚み方向となる。
本発明の樹脂成形体として好適な形状は、ディスク状や角形等の平板状、円柱状、角柱状等の他、曲面を有する形状や、図1に示すようなディスク状等の前記形状の成形体が複数形成された樹脂成形体等を例示することができる。
上記欠陥は、これに限定されるものではないが、最大直径が0.5mm以上の凹状欠陥や気泡、或いは最大長さが0.5mm以上の亀裂等であり、例えば図4に示すような欠陥を特に例示できる。
なお、本発明の第二の付加反応型ポリイミド樹脂成形体においては、15mm以上の厚物成形体であることから、表面を研磨する等の処理により表面欠陥を取り除くことも可能であり、必ずしも第一の付加反応型ポリイミド樹脂成形体について規定するように、表面の欠陥が著しく低減されていなくてもよい。
本発明の樹脂成形体を構成する付加反応型ポリイミド樹脂は、末端に付加反応基を有する芳香族ポリイミドオリゴマーから成り、従来公知の製法により調製したものを使用することができる。例えば、芳香族テトラカルボン酸二無水物、芳香族ジアミン、及び分子内に付加反応基と共に無水物基又はアミノ基を有する化合物を、各酸基の当量の合計と各アミノ基の合計とをほぼ等量となるように使用して、好適には溶媒中で反応させることによって容易に得ることができる。反応の方法としては、100℃以下、好適には80℃以下の温度で、0.1~50時間重合してアミド酸結合を有するオリゴマーを生成し、次いでイミド化剤によって化学イミド化する方法や、140~270℃程度の高温で加熱して熱イミド化する2工程からなる方法、或いは始めから140~270℃の高温で、0.1~50時間重合・イミド化反応を行わせる1工程からなる方法を例示できる。
これらの反応で用いる溶媒は、これに限定されないが、N-メチル-2-ピロリドン、N,N-ジメチルホルムアミド、N,N-ジメチルアセトアミド、N,N-ジエチルアセトアミド、γ-ブチルラクトン、N-メチルカプロラクタム等の有機極性溶媒を好適に使用できる。
これらの付加反応基は、分子内に付加反応基と共に無水物基又はアミノ基を有する化合物が、芳香族イミドオリゴマーの末端のアミノ基又は酸無水物基と、好適にはイミド環を形成する反応によって、芳香族イミドオリゴマーの末端に導入される。
分子内に付加反応基と共に無水物基又はアミノ基を有する化合物は、例えば4-(2-フェニルエチニル)無水フタル酸、4-(2-フェニルエチニル)アニリン、4-エチニル-無水フタル酸、4-エチニルアニリン、ナジック酸無水物、マレイン酸無水物等を好適に使用することができる。
繰返し単位の繰返し数の調整は、芳香族テトラカルボン酸二無水物、芳香族ジアミン、及び分子内に付加反応基と共に無水物基又はアミノ基を有する化合物の割合を変えることにより行うことができ、分子内に付加反応基と共に無水物基又はアミノ基を有する化合物の割合を高くすることにより、低分子量化して繰返し単位の繰返し数は小さくなり、この化合物の割合を小さくすると、高分子量化して繰返し単位の繰返し数は大きくなる。
本発明の樹脂成形体の製造方法は、付加反応型ポリイミド樹脂のプレポリマーを該付加反応型ポリイミド樹脂の増粘開始温度以上の温度で保持し、増粘開始温度より10℃低い温度条件下における溶融粘度を70~900kPa・sに上昇させる増粘工程、該増粘工程を経た付加反応型ポリイミド樹脂を粉体化し混合する粉砕混合工程、該粉体化された付加反応型ポリイミド樹脂を付加反応型ポリイミド樹脂の熱硬化温度以上の温度で賦形する賦形工程、とから成る。
増粘工程においては、まず付加反応型ポリイミド樹脂のプレポリマー(イミドオリゴマー)を、電気炉等を用いて、付加反応型ポリイミド樹脂の増粘開始温度以上の温度で一定時間保持することによって、溶融粘度を70~900kPa・sに上昇させる、好適には増粘開始温度より15~45℃高い温度範囲で50~200分間、特に65~110分間保持することにより、増粘開始温度より10℃低い温度条件下における、プレポリマーの溶融粘度を70~900kPa・sに上昇させる。
プレポリマーを、上記温度条件で一定時間保持することにより、プレポリマーが徐々に架橋し始めることから粘度は上昇する。また上記範囲の加熱温度及び保持時間にすることで、プレポリマーを完全に架橋硬化させることなく、粘度のみを上記範囲に上昇させることが可能になる。従って、増粘工程は、プレポリマーの増粘開始温度以上、且つ、完全に架橋硬化する温度未満にて行う。
尚、付加反応型ポリイミド樹脂においては、反応開始温度は付加反応基に依存し、本発明において付加反応基として好適なフェニルエチニル基を有するポリイミド樹脂においては、増粘開始温度近傍である320±15℃の温度で一定時間保持することによって、溶融粘度を70~900kPa・sに上昇させることが望ましい。
増粘工程を経て得られた増粘開始温度より10℃低い温度条件下における溶融粘度が70~900kPa・sに調整された付加反応型ポリイミド樹脂の塊は、上述した通り、塊の位置によって粘度に差があることから、本発明においては、これを粉砕混合して粉体状の成形前駆体にする。
粉砕混合は、ヘンシェルミキサー、タンブラーミキサー、リボンブレンダ―、ジェットミル、ローラーミル、ボールミル、スパイクミル、振動ミル等の従来公知の粉砕混合機を用いることもできるが、粉砕及び混合を同時に効率よく行うことができることから、ヘンシェルミキサーを用いることが特に好適である。
粉体状成形前駆体の粒度は、レーザ散乱回折法により測定した平均粒径(D50)が1~1000μmの範囲にあることが好適である。
前述したとおり、本発明の成形前駆体においては、付加反応型ポリイミド樹脂の増粘開始温度から10℃低い温度条件下において70~900kPa・sの溶融粘度を有することから、樹脂成形体の成形に際しては、粉砕混合された粉体状の成形前駆体をそのまま付加反応型ポリイミドの熱硬化温度以上の温度で賦形することができる。
また粉砕された成形前駆体の温度を均一化するために、必要により、粉体状の成形前駆体を成形型に導入した後、成形型内で溶融温度以上増粘開始温度以下の温度で所定時間、好適には増粘開始温度より5~20℃低い温度で10~30分保持する、予備加熱工程を設けることもできる。
尚、賦形は、5mm以上の厚みの成形体を成形するという見地からは、成形型に導入された混合物を加圧圧縮して成形する圧縮成形やトランスファー成形によることが好適であるが、射出成形や押出成形により成形してもよい。
用いる付加反応型ポリイミド樹脂の増粘開始温度をレオメータにより計測した。目標温度への到達速度を4℃/minとし、目標到達温度到達後120分保持する温度条件下で、パラレルプレートを用い、角周波数100rad/s、ひずみ10%として溶融粘度を測定し、最低溶融粘度を示す時間を0分とし、横軸を時間(min)、縦軸を溶融粘度(Pa・s)とした片対数グラフにプロットし、指数近似式より式(1)の係数Bを求める。付加重合ポリイミド(宇部興産社製PETI-330)において、目標温度が285℃の時のB値が0.0092であり、目標温度が290℃の時のB値が0.0141であり、増粘開始温度を290℃とした。
用いる付加反応型ポリイミド樹脂の増粘開始温度より10℃低い温度における溶融粘度をレオメータ(TA instrument社製ARES-G2)により測定した。パラレルプレートを用い、(測定ギャップを1mm)ひずみを1%、角周波数範囲を0.1~100rad/sとして、溶融粘度を測定したときの、0.1rad/sにおける溶融粘度を測定値とした。尚、測定する際は、粉体状の成形前駆体をホットプレスにて、増粘開始温度より10℃~40℃低い温度で加熱加圧し平滑な板状にした。
JIS K 7171(プラスチック-曲げ特性の試験方法)に準拠し、オートグラフ(島津製作所製 AG-1/50N-10kN)を用い、樹脂成形体から切り出した試験片(長さ50mm×幅10mm×厚み3mm)について試験速度1mm/minで曲げ試験を行い、曲げ強度を測定した。
尚、樹脂成形体上面から厚み方向に、3mm、中立面から±1.5mm、成形体下面から3mmの位置で試験片を切り出した。
欠陥の有無、個数を目視で確認し、サイズを定規、ノギス等の計測器具で測定した。成形体の全表面に存在する0.5mm以上の欠陥の数が1個/100cm2以下であれば良(〇)とし、1個/100cm2より多い場合は(×)とした。
357℃の温度で6時間加熱前後の付加反応型ポリイミド樹脂成形体の最大厚みを、ノギス、ハイトゲージ等の計測器具で測定した。厚み差が1mm未満であれば良(〇)とし、1mm以上の場合は(×)とした。
付加反応型ポリイミド(宇部興産社製PETI-330)を、電気炉内での樹脂温度330℃、65分保持し、溶融粘度を付加反応型ポリイミドの増粘開始温度から10℃低い温度である280℃における溶融粘度126.6kPa・sに調整した。その後、急冷し、室温まで冷却された付加反応型ポリイミド樹脂の塊を得た。得られた樹脂塊を粉砕混合機で粉砕混合してから圧縮成形型に供給し280℃、90分予備加熱をした後、11.0MPaに加圧しながら昇温速度0.3℃/minで320℃まで昇温し、60分間保持、さらに昇温速度0.43℃/minで371℃まで昇温、120分間保持後、徐冷してφ200mm厚さ5mmのディスク状の板を得た。
電気炉内での樹脂温度330℃、保持時間を95分に変更し、溶融粘度を付加反応型ポリイミドの増粘開始温度から10℃低い温度である280℃における溶融粘度642.9kPa・sに調整した以外は実施例1と同じとした。
成形品の厚みを表1に示す厚みとした以外は実施例1と同様にした。
成形品の厚みを表1に示す厚みとした以外は実施例2と同様とした。
電気炉内での樹脂温度330℃、保持時間を110分に変更し粘度調整した以外は実施例11と同じとした。尚、粘度調整した付加反応型ポリイミド樹脂の、増粘開始温度から10℃低い温度である280℃における溶融粘度は測定不可であったため、レオメータ内で増粘工程を再現した。レオメータ内で280℃から3.1℃/minで昇温し、330℃に到達した時点を0分として、110分経過した時点での複素粘度の値、896.3kPa・sを溶融粘度とした。測定にはφ25mmのパラレルプレートを使用し、角周波数を10rad/sに設定した。
電気炉内での樹脂温度を330℃、保持時間を120分に変更し、粘度調整した以外は、実施例11と同様にした。尚、粘度調整した付加反応型ポリイミド樹脂の、増粘開始温度から10℃低い温度である280℃における溶融粘度は測定不可であったため、レオメータ内で増粘工程を再現した。レオメータ内で280℃から3.1℃/minで昇温し、330℃に到達した時点を0分として、120分経過した時点での複素粘度の値、1151.1kPa・sを溶融粘度とした。測定にはφ25mmのパラレルプレートを使用し、角周波数を10rad/sに設定した。
付加反応型ポリイミド(宇部興産社製PETI-330)を、圧縮成形型に供給し、金型温度280℃、90分予備加熱をした後、3.3℃/minで320℃まで昇温し、金型温度320℃で45分保持して、圧縮成形時に樹脂漏れの生じない粘度になるまで上昇させた後、11.0MPaに加圧しながら昇温速度0.85℃/minで371℃まで昇温、120分間保持後、徐冷してφ200mm厚さ3mmのディスク状の板を得た。
成形品の厚みを5mmとした以外は、比較例1と同様にした。
金型温度を320℃、保持時間を40分に変更し、成形品の厚さを表2に示す厚みとした以外は、比較例1と同様にした。
電気炉内での樹脂温度を330℃、保持時間を60分に変更し、溶融粘度を付加反応型ポリイミドの増粘開始温度から10℃低い温度である280℃における溶融粘度60.4kpa・sに調整した以外は、実施例11と同様にした。
実施例5~14、比較例1,4~7にて得られた成形品の曲げ強度を表1及び表2に示す。
比較例7で得られた成形品の側面の拡大写真を図4に示す。図4から明らかなように、2~3mmのボイドが多数発生し、ボイド同士がつながってひびのようになっている箇所もあった。
また上記後加熱評価後の表面写真を図5に示す。図5(A)は圧縮面、(B)は側面をそれぞれ示す。図5から明らかなように、凸状に変形した箇所があった。
更に比較例5及び7で得られた成形品の厚み方向の断面を図6及び7にそれぞれ示す。図6から明らかなように、15mmの成形品である比較例5では、内部ボイドが部分的に複数形成されていた。また図7から明らかなように、厚み30mmの成形品である比較例7では、内部ボイドが全体的に多数存在していた。
Claims (11)
- 5mm以上の厚みを有する付加反応型ポリイミド樹脂成形体であって、成形体の全表面に存在する0.5mm以上の欠陥の数が1個/100cm2以下であることを特徴とする付加反応型ポリイミド樹脂成形体。
- 15mm以上の厚みを有する付加反応型ポリイミド樹脂成形体であって、曲げ強度が60MPa以上であることを特徴とする付加反応型ポリイミド樹脂成形体。
- 前記欠陥が、最大直径が0.5mm以上の凹部又は気泡、或いは長さ0.5mm以上の亀裂である請求項1記載の付加反応型ポリイミド樹脂成形体。
- 曲げ強度が60MPa以上である請求項1又は3記載の付加反応型ポリイミド樹脂成形体。
- 前記付加反応型ポリイミド樹脂が、付加反応基としてフェニルエチニル基を有するポリイミド樹脂である請求項1~4の何れかに記載の付加反応型ポリイミド樹脂成形体。
- 成形体の形状が、厚みが5~30mmのディスク状又は矩形状の平板状である請求項1~5の何れかに記載の付加反応型ポリイミド樹脂成形体。
- 温度357℃で6時間加熱した場合に、変形を生じないか、或いは高さが1mm未満の凸状変形を生じる請求項1~6の何れかに記載の付加反応型ポリイミド樹脂成形体。
- 付加反応型ポリイミド樹脂のプレポリマーを該付加反応型ポリイミド樹脂の増粘開始温度以上の温度で保持し、増粘開始温度より10℃低い温度条件下における溶融粘度を70~900kPa・sに上昇させる増粘工程、該増粘工程を経た付加反応型ポリイミド樹脂を粉体化し混合する粉砕混合工程、該粉体化された付加反応型ポリイミド樹脂を付加反応型ポリイミド樹脂の熱硬化温度以上の温度で賦形する賦形工程、とから成ることを特徴とする付加反応型ポリイミド樹脂成形体の製造方法。
- 前記増粘工程において、前記付加反応型ポリイミド樹脂を増粘開始温度より15~45℃高い温度範囲で50~200分間保持する請求項8記載の付加反応型ポリイミド樹脂成形体の製造方法。
- 前記賦形工程が、圧縮成形により行われる請求項8又は9記載の付加反応型ポリイミド樹脂成形体の製造方法。
- 付加反応型ポリイミド樹脂から成り、該付加反応型ポリイミド樹脂の増粘開始温度から10℃低い温度条件下における溶融粘度が70~900kPa・sであることを特徴とする成形前駆体。
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