WO2023026817A1 - 熱硬化性樹脂組成物、及び、熱硬化物 - Google Patents
熱硬化性樹脂組成物、及び、熱硬化物 Download PDFInfo
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- WO2023026817A1 WO2023026817A1 PCT/JP2022/030009 JP2022030009W WO2023026817A1 WO 2023026817 A1 WO2023026817 A1 WO 2023026817A1 JP 2022030009 W JP2022030009 W JP 2022030009W WO 2023026817 A1 WO2023026817 A1 WO 2023026817A1
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- thermosetting resin
- resin composition
- resin
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- NNOBHPBYUHDMQF-UHFFFAOYSA-N propylphosphine Chemical compound CCCP NNOBHPBYUHDMQF-UHFFFAOYSA-N 0.000 description 1
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- 150000003377 silicon compounds Chemical class 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
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- 239000000600 sorbitol Substances 0.000 description 1
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- 238000003756 stirring Methods 0.000 description 1
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- 150000005846 sugar alcohols Chemical class 0.000 description 1
- TXDNPSYEJHXKMK-UHFFFAOYSA-N sulfanylsilane Chemical compound S[SiH3] TXDNPSYEJHXKMK-UHFFFAOYSA-N 0.000 description 1
- 150000003457 sulfones Chemical class 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- KUCOHFSKRZZVRO-UHFFFAOYSA-N terephthalaldehyde Chemical compound O=CC1=CC=C(C=O)C=C1 KUCOHFSKRZZVRO-UHFFFAOYSA-N 0.000 description 1
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- UFDHBDMSHIXOKF-UHFFFAOYSA-N tetrahydrophthalic acid Natural products OC(=O)C1=C(C(O)=O)CCCC1 UFDHBDMSHIXOKF-UHFFFAOYSA-N 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- SRPWOOOHEPICQU-UHFFFAOYSA-N trimellitic anhydride Chemical compound OC(=O)C1=CC=C2C(=O)OC(=O)C2=C1 SRPWOOOHEPICQU-UHFFFAOYSA-N 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- HGBOYTHUEUWSSQ-UHFFFAOYSA-N valeric aldehyde Natural products CCCCC=O HGBOYTHUEUWSSQ-UHFFFAOYSA-N 0.000 description 1
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- 239000000811 xylitol Substances 0.000 description 1
- HEBKCHPVOIAQTA-SCDXWVJYSA-N xylitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)CO HEBKCHPVOIAQTA-SCDXWVJYSA-N 0.000 description 1
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- FYGDTMLNYKFZSV-BYLHFPJWSA-N β-1,4-galactotrioside Chemical compound O[C@@H]1[C@@H](O)[C@H](O)[C@@H](CO)O[C@H]1O[C@@H]1[C@H](CO)O[C@@H](O[C@@H]2[C@@H](O[C@@H](O)[C@H](O)[C@H]2O)CO)[C@H](O)[C@H]1O FYGDTMLNYKFZSV-BYLHFPJWSA-N 0.000 description 1
Images
Classifications
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- 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
- C08J3/16—Powdering or granulating by coagulating dispersions
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
- C08K3/36—Silica
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- 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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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L79/00—Compositions 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 C08L61/00 - C08L77/00
- C08L79/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
- C08L79/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L81/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
- C08L81/06—Polysulfones; Polyethersulfones
Definitions
- thermosetting resin compositions and thermosets relate to thermosetting resin compositions and thermosets.
- a curable resin composition containing a curable resin and resin particles has been used from the viewpoint of increasing the toughness of a cured product obtained by curing the curable resin composition (for example, Patent Document 1).
- thermosetting resin composition containing a thermosetting resin and resin particles was used to prepare a thermoset by changing the curing temperature. was found to be lower. If the toughness of the thermoset changes depending on the curing temperature, a difference in toughness may occur between the surface and the inside of the thermoset. In particular, when the thermoset is large, the difference in toughness may become large. In addition, when the thermosets are produced sequentially, there may be some deviation in the curing temperature in time series, but due to this deviation, the thermosets obtained first and the thermosets obtained later difference in toughness may occur. Therefore, a curable resin composition whose toughness does not easily change even when the curing temperature changes, and a thermoset product obtained by thermally curing the curable resin composition can be demanded.
- an object of the present disclosure is to provide a curable resin composition in which the toughness of the thermoset does not easily change even if the curing temperature changes, and a thermoset obtained by thermosetting the curable resin composition. do.
- the first aspect of the present disclosure has a first resin, which is a thermosetting resin, and composite particles,
- the composite particles contain a second resin and an inorganic filler, It relates to a thermosetting resin composition, wherein the amount of the inorganic filler in the total amount of the second resin and the inorganic filler is 0.1 to 70% by weight.
- the inorganic filler contains at least one selected from the group consisting of silica, titanium oxide, zinc oxide, bentonite, kaolin and carbon black.
- the second resin contains at least one selected from the group consisting of polyamide resin, polyimide resin, and polyethersulfone resin.
- the composite particles have a median diameter of 1 to 100 ⁇ m.
- the sphericity of the composite particles is 95% or more.
- the retention rate of plane strain fracture toughness (K IC ) determined by the following formula is 85% or more.
- Retention rate of plane strain fracture toughness (K IC ) (plane strain fracture toughness (K IC ) of a cured product obtained by curing the thermosetting resin composition at 200 ° C.) / (the thermosetting resin composition is 175
- the first resin contains at least one selected from the group consisting of epoxy resins and phenolic resins.
- the composite particles are 1 to 20 parts by weight with respect to 100 parts by weight of the first resin.
- the second aspect of the present disclosure relates to a thermoset product obtained by thermosetting the thermosetting resin composition.
- thermosetting the curable resin composition it is possible to provide a curable resin composition in which the toughness of the thermoset does not easily change even when the curing temperature changes, and a thermoset obtained by thermosetting the curable resin composition.
- each configuration and combination thereof in each embodiment is an example, and addition, omission, replacement, and other changes of configuration are possible as appropriate without departing from the gist of the present disclosure.
- This disclosure is not limited by the embodiments, but only by the scope of the claims. Also, each aspect disclosed in this specification may be combined with any other feature disclosed in this specification.
- thermosetting resin composition according to this embodiment has a first resin, which is a thermosetting resin, and composite particles.
- the composite particles contain a second resin and an inorganic filler.
- the amount of the inorganic filler in the total amount of the second resin and the inorganic filler is 0.1 to 70% by weight.
- thermosetting resin examples include epoxy resin, phenol resin, unsaturated polyester resin, vinyl ester resin, acrylic resin, urea resin, melamine resin, aniline resin, polyimide resin, bismaleimide resin, and the like. mentioned. These thermosetting resins may be used alone or in combination of two or more.
- thermosetting resin epoxy resin and phenol resin are preferable, and epoxy resin is particularly preferable.
- epoxy resins include glycidyl ether-type epoxy resins, glycidylamine-type epoxy resins, glycidyl ester-type epoxy resins, alkene oxides (eg, vinylcyclohexene dioxide), and triglycidyl isocyanurate.
- Examples of the glycidyl ether type epoxy resin include bisphenol type epoxy resin, phenol type epoxy resin, dicyclopentadiene type epoxy resin, epoxy resin having an aromatic skeleton (polyglycidyl ether), alkanediol diglycidyl ether, and polyalkanediol.
- Diglycidyl ethers, epoxy resins having an aliphatic skeleton (polyglycidyl ethers), and the like are included.
- the bisphenol-type epoxy resin examples include reaction products of bisphenols and epichlorohydrin, reaction products of alkylene oxide adducts of bisphenols and epichlorohydrin, and the like.
- the bisphenols include bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, brominated bisphenol type epoxy resin and the like.
- the number of moles of the alkylene oxide added to 1 mole of the hydroxyl group of the bisphenol is, for example, 1 mol or more (eg, 1 to 20 mol), preferably 1 to 15 mol, more preferably 1 ⁇ 10 moles.
- phenol-type epoxy resin examples include phenol novolac-type epoxy resin, cresol novolak-type epoxy resin, naphthol novolak-type epoxy resin, bisphenol A novolac-type epoxy resin, bisphenol F novolak-type epoxy resin, biphenyl skeleton-containing phenol novolak resin, and xylylene. Skeleton-containing phenol novolak resins and the like can be mentioned.
- Examples of the epoxy resin (polyglycidyl ether) having an aromatic skeleton include glycidyl ether having a naphthalene skeleton.
- Examples of the glycidyl ether having a naphthalene skeleton include di(glycidyloxy)naphthalene and bis[2,7-di(glycidyloxy)naphthyl]methane.
- Examples of the di(glycidyloxy)naphthalene include 1,5-di(glycidyloxy)naphthalene.
- alkanediol diglycidyl ethers examples include C 2-10 alkanediol diglycidyl ethers.
- Examples of the C 2-10 alkanediol diglycidyl ether include butanediol diglycidyl ether, neopentyl glycol diglycidyl ether, 1,6-hexanediol diglycidyl ether and the like.
- polyalkanediol diglycidyl ethers examples include poly-C 2-4 alkanediol diglycidyl ethers.
- poly-C 2-4 alkanediol diglycidyl ether examples include polypropylene glycol diglycidyl ether.
- Examples of the epoxy resin (polyglycidyl ether) having an aliphatic skeleton include glycidyl polyethers of polyols.
- Examples of the polyol include alkanetriol, alkanetetraol, alkanepentaol, and alkanehexaol.
- Examples of the alkanetriol include C 3-10 alkanetriol.
- Examples of the alkanetetraol include C 3-10 alkanetetraol.
- Examples of the glycidyl polyether include diglycidyl ether, triglycidyl ether, tetraglycidyl ether, pentaglycidyl ether, and hexaglycidyl ether.
- Examples of the glycidyl polyether of the polyol include trimethylolpropane diglycidyl ether, trimethylolpropane triglycidyl ether, glycerin diglycidyl ether, glycerin triglycidyl ether and the like.
- Examples of the glycidylamine-type epoxy resin include tetraglycidyldiaminodiphenylmethane, triglycidyl-p-aminophenol, triglycidylaminocresol, diglycidylaniline, N,N-diglycidyl-4-glycidyloxyaniline, and the like.
- Examples of the glycidyl ester type epoxy resin include diglycidyl ester of dicarboxylic acid.
- Examples of the dicarboxylic acid include aromatic dicarboxylic acids and hydrogenated aromatic dicarboxylic acids.
- Examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid and the like.
- epoxy resins may be used alone or in combination of two or more.
- epoxy resins having an aromatic skeleton are preferred, and bisphenol-type epoxy resins are particularly preferred, in terms of strength and the like.
- phenolic resin examples include resins having one or more, preferably two or more, phenolic hydroxyl groups in one molecule.
- examples of the phenol resins include novolak phenol resins, resol phenol resins, and polyoxystyrene resins.
- the novolac-type phenolic resin is a condensate of phenols, aldehydes and the like.
- the novolac-type phenolic resin is obtained, for example, by condensation polymerization of phenols and aldehydes in the presence of an acidic catalyst.
- the resol-type phenolic resin is a condensate of phenols, aldehydes and the like.
- the resol-type phenolic resin is obtained, for example, by condensation polymerization of phenols and aldehydes in the presence of an alkaline catalyst.
- phenols examples include phenol, cresol, trimethylphenol, xylenol, resorcinol, catechol, butylphenol, octylphenol, nonylphenol, phenylphenol, dihydroxybenzene, bisphenol A and naphthol.
- cresol examples include o-cresol, m-cresol and p-cresol.
- trimethylphenol examples include 2,3,5-trimethylphenol.
- Examples of the xylenol examples include 2,3-xylenol, 2,4-xylenol, 2,5-xylenol, 3,4-xylenol and 3,5-xylenol.
- aldehydes examples include formaldehyde, paraformaldehyde, acetaldehyde, benzaldehyde, hydroxybenzaldehyde, glyoxal, glutaraldehyde, terephthalaldehyde, isophthalaldehyde, propionaldehyde, butyraldehyde, isobutyraldehyde, 3-methylbutyraldehyde, and p-tolylaldehyde. , phenylacetaldehyde and the like.
- the hydroxybenzaldehyde includes o-hydroxybenzaldehyde, m-hydroxybenzaldehyde and p-hydroxybenzaldehyde.
- novolak-type phenol resin examples include novolak resin (condensate of phenol and formaldehyde), cresol novolak resin (condensate of cresol and formaldehyde), and the like.
- the phenol resin may be used singly or in combination of two or more.
- the hydroxyl equivalent of the phenol resin is preferably 50-500 g/eq. More preferably 100-350 g/eq. is.
- thermosetting resin composition according to this embodiment preferably contains 40 to 99% by weight, more preferably 80 to 97% by weight of the first resin, which is a thermosetting resin.
- the composite particles contain a second resin and an inorganic filler.
- Examples of the second resin include polyamide resin, polyimide resin, polyethersulfone resin, and the like.
- polyamide resins examples include aliphatic polyamide resins, alicyclic polyamide resins, and aromatic polyamide resins.
- the polyamide resin may be a homopolyamide resin or a copolyamide resin.
- terminal groups of the polyamide resin include amino groups, carboxyl groups, acid anhydride groups, and the like.
- aliphatic polyamide resin examples include a polyamide of an aliphatic diamine component and an aliphatic dicarboxylic acid component, a lactam polyamide, an aminocarboxylic acid polyamide, an aliphatic diamine component, an aliphatic dicarboxylic acid component and a lactam and/or aminocarboxylic acid. and polyamide resins.
- aliphatic diamine component examples include C4-16 alkylenediamine (eg, tetramethylenediamine, hexamethylenediamine, dodecanediamine, etc.). Said aliphatic diamine component is preferably a C6-14 alkylenediamine, more preferably a C6-12 alkylenediamine.
- aliphatic dicarboxylic acid component examples include C4-20 alkanedicarboxylic acids (eg, adipic acid, sebacic acid, dodecanedioic acid, etc.). Said aliphatic dicarboxylic acid component is preferably a C5-16 alkanedicarboxylic acid, more preferably a C6-14 alkanedicarboxylic acid.
- lactams examples include lactams having 4 to 20 carbon atoms (eg, ⁇ -caprolactam, ⁇ -laurolactam, etc.).
- the lactam is preferably a lactam having 4 to 16 carbon atoms.
- aminocarboxylic acid examples include C4-20 aminocarboxylic acid (eg, ⁇ -aminoundecanoic acid, etc.). Said aminocarboxylic acid is preferably a C4-16 aminocarboxylic acid, more preferably a C6-14 aminocarboxylic acid.
- Examples of the aliphatic polyamide include polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 66, polyamide 610, polyamide 611, polyamide 612, polyamide 613, polyamide 1010, polyamide 66/11, polyamide 66/12, polyamide 6/12/612 and the like.
- the alicyclic polyamide examples include polyamides containing at least one component selected from an alicyclic diamine component and an alicyclic dicarboxylic acid component.
- an alicyclic diamine component and/or an alicyclic dicarboxylic acid component as well as an aliphatic diamine component and/or an aliphatic dicarboxylic acid component exemplified above are used.
- Cyclic polyamide resins are preferred.
- Such alicyclic polyamide resins have high transparency and are known as so-called transparent polyamides.
- Examples of the alicyclic diamine component include diaminocycloalkane, bis(aminocycloalkyl)alkane, and hydrogenated xylylenediamine.
- Examples of the diaminocycloalkane include diaminocyclohexane. Said diaminocycloalkane is preferably diamino C5-10 cycloalkane.
- Examples of the bis(aminocycloalkyl)alkane include bis(4-aminocyclohexyl)methane, bis(4-amino-3-methylcyclohexyl)methane, 2,2-bis(4′-aminocyclohexyl)propane, and the like. mentioned.
- Said bis(aminocycloalkyl)alkane is preferably bis(aminoC5-8cycloalkyl)C1-3alkane.
- the alicyclic diamine component may have a substituent such as an alkyl group.
- the alkyl group is preferably a C1-6 alkyl group, more preferably a C1-4 alkyl group, still more preferably a C1-2 alkyl group (methyl group, ethyl group, etc.).
- alicyclic dicarboxylic acid examples include cycloalkanedicarboxylic acids (eg, cyclohexane-1,4-dicarboxylic acid, cyclohexane-1,3-dicarboxylic acid, etc.).
- cycloalkanedicarboxylic acids eg, cyclohexane-1,4-dicarboxylic acid, cyclohexane-1,3-dicarboxylic acid, etc.
- Typical alicyclic polyamides include, for example, an alicyclic diamine component [eg, bis(aminocyclohexyl)alkane] and an aliphatic dicarboxylic acid component [eg, alkanedicarboxylic acid (eg, C4-20 alkanedicarboxylic acid component etc.)] and the like.
- an alicyclic diamine component eg, bis(aminocyclohexyl)alkane
- an aliphatic dicarboxylic acid component eg, alkanedicarboxylic acid (eg, C4-20 alkanedicarboxylic acid component etc.)] and the like.
- the aromatic polyamide is a concept including polyamides containing at least one of an aromatic diamine component and an aromatic dicarboxylic acid component as structural units.
- the aromatic polyamide include polyamides in which both the diamine component of the structural unit and the dicarboxylic acid component of the structural unit are aromatic components (also called “wholly aromatic polyamide", "aramid”, etc.).
- the aromatic polyamide may be a modified polyamide. Examples of modified polyamides include polyamides having a branched chain structure. Examples of the aromatic diamine component include meta-xylylenediamine. Examples of the aromatic dicarboxylic acid component include terephthalic acid and isophthalic acid. Further, the aromatic dicarboxylic acid component may be a dimer acid or the like.
- the polyimide resin preferably contains a bismaleimide compound having at least two unsaturated N-substituted maleimide groups in its molecular structure.
- the polyimide resin include N,N'-ethylenebismaleimide, N,N'-hexamethylenebismaleimide, N,N'-(1,3-phenylene)bismaleimide, N,N'-[1,3- (2-methylphenylene)]bismaleimide, N,N'-[1,3-(4-methylphenylene)]bismaleimide, N,N'-(1,4-phenylene)bismaleimide, bis(4-maleimide phenyl)methane, bis(3-methyl-4-maleimidophenyl)methane, 3,3-dimethyl-5,5-diethyl-4,4-diphenylmethane bismaleimide, bis(4-maleimidophenyl) ether, bis(4- maleimidophenyl)sulfone, bis(4
- polyethersulfone resin examples include polyethersulfone resins containing 4,4'-dichlorophenylsulfone and 1,4-dihydroxyphenyl as structural units.
- second resins may be used alone or in combination of two or more.
- a semi-crystalline polyamide eg, alicyclic polyamide, aliphatic polyamide, etc.
- a semi-crystalline polyamide eg, alicyclic polyamide, aliphatic polyamide, etc.
- the number average molecular weight of the second resin is, for example, 8,000 to 200,000, preferably 9,000 to 150,000, more preferably 10,000 to 100,000.
- the number average molecular weight is measured from polystyrene-equivalent molecular weight distribution using gel permeation chromatography (GPC) using a chloroform eluent.
- GPC gel permeation chromatography
- a column suitable for measuring the molecular weight may be used as the column in the GPC.
- the melting point of the second resin is, for example, 150°C or higher (eg, 155 to 350°C), preferably 160°C or higher (eg, 165 to 300°C), and more preferably 170°C or higher (eg, 175 to 270°C).
- the melting point can be measured using, for example, a differential scanning calorimeter (DSC). More specifically, first, about 5 mg of a sample for measuring the melting point is prepared, and two metal (for example, aluminum) containers having the same shape and the same weight are prepared. Then, one of the two said containers is filled with the sample while the other container is left empty. Then, a container containing the sample and an empty container as a reference are set in the DSC, and the temperature of the sample is increased at a temperature increase rate of 10 ° C./min while flowing nitrogen gas. From the DSC curve obtained Melting point can be determined. The melting point can be determined by performing differential scanning calorimetry twice on the same sample, and determined as the peak value of the second DSC curve.
- DSC differential scanning calorimeter
- the glass transition temperature (Tg) of the second resin is, for example, 30°C or higher (eg, 50 to 200°C), preferably 100 to 150°C, more preferably 110 to 145°C (especially 120 to 140°C).
- the glass transition temperature (Tg) means the midpoint glass transition temperature measured using a differential scanning calorimeter (DSC).
- the midpoint glass transition temperature can be determined based on the method described in JIS K7121-1987 "Method for measuring transition temperature of plastics". That is, first, about 5 mg of a sample for measuring the midpoint glass transition temperature is prepared, and two metal (for example, aluminum) containers having the same shape and the same weight are prepared. Then, one of the two said containers is filled with the sample while the other container is left empty. Then, a container containing the sample and an empty container as a reference are set in the DSC, and the temperature of the sample is increased at a temperature increase rate of 10 ° C./min while flowing nitrogen gas. From the DSC curve obtained A midpoint glass transition temperature can be determined.
- the degree of crystallinity of the second resin is preferably 80% or less (eg 1 to 75%), more preferably 50% or less (eg 10 to 50%).
- crystallinity can be measured based on wide angle X-ray diffraction (WAXD).
- WAXD wide angle X-ray diffraction
- PXL Ver2.3.1.0 powder X-ray analysis software
- fitting to the diffraction curve obtained by wide-angle X-ray diffraction (method: FP method, peak shape: logarithmic normal distribution , background refinement: none)
- the crystal diffraction peak and amorphous halo are separated, and the degree of crystallinity (%) can be obtained from the following formula.
- Crystallinity [integrated intensity sum of crystalline diffraction peaks (cps deg)]/[integrated intensity sum of crystalline diffraction peaks and amorphous halos (cps deg)] ⁇ 100%
- the composite particles preferably contain 50 to 99.5% by weight, more preferably 60 to 99% by weight, and even more preferably 70 to 95% by weight of the second resin.
- inorganic substances constituting the inorganic filler include silica, titanium oxide, zinc oxide, bentonite, kaolin, carbon black, calcium carbonate, magnesium carbonate, clay, calcium phosphate, hydroxyapatite, mica, talc, quartz, glass, diatomaceous earth, and nepheline. Night, cristobalite, wollastonite, aluminum hydroxide, iron oxide, aluminum oxide, calcium sulfate, barium sulfate, dolomite, silicon carbide, silicon nitride, boron nitride, graphite and the like.
- silica, titanium oxide, zinc oxide, bentonite, kaolin, and carbon black are preferable.
- silica include fumed silica and colloidal silica.
- thermosetting resin composition since the composite particles contain the inorganic filler, even if the curing temperature changes, the toughness of the thermosetting material does not easily change.
- the inorganic filler may be an inorganic filler surface-treated with an organic silicon compound. That is, in the present embodiment, "inorganic filler” is a concept including "inorganic filler surface-treated with an organosilicon compound".
- organosilicon compound include hexamethyldisilazane, dimethyldichlorosilane, octylsilane, silicone oil, dimethylpolysiloxane, aminosilane, aminoalkylsilane, methacrylsilane, acrylsilane, vinylsilane, phenylsilane, mercaptosilane, and epoxysilane. , silane coupling agents, and the like.
- the median diameter of the inorganic filler is preferably 0.01 to 100 ⁇ m, more preferably 0.1 to 100 ⁇ m, even more preferably 1 to 50 ⁇ m, still more preferably 8 to 20 ⁇ m.
- the median diameter of the inorganic filler can be determined as follows. First, an image is obtained by photographing the inorganic filler with a scanning electron microscope (SEM). Next, 30 or more inorganic fillers in the image are randomly selected, and the area of each selected inorganic filler is determined. When the number of inorganic fillers in the image is less than 30, the area of each inorganic filler is determined. Then, let the diameter of a perfect circle having the same area as each of the determined areas be the diameter of each inorganic filler.
- the median diameter of the obtained inorganic filler is defined as the median diameter.
- the median diameter of the inorganic filler means the number-based median diameter of the inorganic filler.
- the inorganic filler is contained in the inorganic filler as secondary particles in which a plurality of primary particles are aggregated, and the "median diameter of the inorganic filler" refers to the median diameter of the inorganic filler including the secondary particles. means.
- the amount of the inorganic filler in the total amount of the second resin and the inorganic filler is 0.1-70% by weight, preferably 1-50% by weight, more preferably 5-40% by weight.
- the inorganic filler contains "an inorganic filler surface-treated with an organosilicon compound"
- the amount of the inorganic filler also includes the amount of the organosilicon compound.
- the composite particles may further contain an additive.
- the additives include stabilizers, colorants, dispersants, preservatives, antioxidants, antifoaming agents and the like.
- the additives may be used alone or in combination of two or more.
- the total content of the additives is, for example, 10 parts by weight or less (eg, 0.01 to 10 parts by weight) with respect to 100 parts by weight of the second resin.
- the median diameter of the composite particles can be selected, for example, from a range of 2 ⁇ m or more (eg, 3 to 40 ⁇ m), preferably 4 ⁇ m or more (eg, 5 to 40 ⁇ m), more preferably 6 ⁇ m or more (eg, 7 to 35 ⁇ m), and still more preferably 8 ⁇ m. or more (for example, 9 to 30 ⁇ m), particularly preferably 10 ⁇ m or more (for example, 11 to 30 ⁇ m).
- the median diameter of the composite particles means a value obtained by dispersing the composite particles in water and measuring with a laser diffraction/scattering particle size distribution analyzer.
- the median diameter of the composite particles means the volume-based median diameter of the composite particles.
- the median diameter of the composite particles means the median diameter of the composite particles of the primary particles.
- the sphericity of the composite particles is preferably 95% or more and 100% or less, more preferably 97% or more and 100% or less, and still more preferably 99% or more and 100% or less.
- the sphericity of particles can be measured by the following method. That is, particles are observed with a scanning electron microscope (SEM), the major axis and minor axis of 30 randomly selected particles are measured, and the minor axis/major axis ratio of each particle is determined. Then, the arithmetic average value of the minor axis/long axis ratio is obtained, and this arithmetic average value is taken as the sphericity of the particles. It should be noted that the closer the sphericity of the particle is to 1, the more spherical the particle can be determined.
- the water absorption of the composite particles is, for example, 2.5% by weight or less, preferably 2.0% by weight or less (eg, 1.5% by weight or less), preferably 2.0% by weight or less (eg, 1.5% by weight or less). % by weight or less), more preferably 1.0% by weight or less (especially 0.8% by weight or less). Further, the water absorption of the composite particles is, for example, 0.01% by weight or more, preferably 0.05% by weight or more (for example, 0.08% by weight or more), preferably 0.055% by weight or more (for example, 0.05% by weight or more). 0.06% by weight or more), more preferably 0.065% by weight or more (especially 0.07% by weight or more).
- thermosetting resin composition according to the present embodiment has an advantage that the composite particles have a water absorption rate of 0.5% by weight or more, so that the toughness is increased.
- thermosetting resin composition according to the present embodiment has the advantage that the composite particles have a water absorption of 2.5% by weight or less, so that the toughness is increased.
- thermosetting resin composition according to the present embodiment can have the advantage that voids are less likely to occur in the composite particles because the water absorption of the composite particles is 2.5% by weight or less.
- the water absorption of composite particles can be measured according to the Karl Fischer method.
- a trace moisture measuring device (“CA-200” manufactured by Mitsubishi Chemical Analytech Co., Ltd.) equipped with a moisture vaporizer (“Model number VA-200” manufactured by Mitsubishi Chemical Analytech Co., Ltd.).
- the measurement temperature can be 210°C.
- the composite particles are preferably 3 to 30 parts by weight, more preferably 5 to 20 parts by weight, with respect to 100 parts by weight of the first resin.
- Method for producing composite particles examples include a freeze pulverization method, a chemical pulverization method, a polymerization method, a forced emulsification method, a laser method, and the like.
- a forced emulsification method is preferable as a method for producing composite particles.
- the forced emulsification method includes a step (A) of obtaining a melt-kneaded product by melt-kneading the second resin, the inorganic filler, and an aqueous medium incompatible with the second resin by heating. a step (B) of cooling the melt-kneaded product; a step (C) of obtaining precursor particles by removing the aqueous medium from the cooled melt-kneaded product with a hydrophilic solvent or water; and a step (D) of obtaining the composite particles by adjusting the water absorption amount of the body particles.
- the aqueous medium used in step (A) is selected according to the type of the second resin.
- the aqueous medium include heat-meltable saccharides and water-soluble polymers.
- the heat-meltable saccharides include oligosaccharides (eg, sucrose, maltotriose, etc.) and sugar alcohols (eg, xylitol, erythritol, sorbitol, mannitol, etc.).
- the water-soluble polymer include water-soluble synthetic polymers (eg, polyethylene glycol, polyvinyl alcohol, sodium polyacrylate, polyacrylamide, etc.), polysaccharides (eg, starch, methylcellulose, etc.), and the like.
- These aqueous media can be used alone or in combination of two or more.
- polyethylene glycol is preferable from the viewpoint that the composite particles can be easily adjusted to an appropriate particle size.
- the weight ratio of the aqueous medium is, for example, 10 to 100 parts by weight, preferably 20 to 100 parts by weight, more preferably 30 to 100 parts by weight, per 100 parts by weight of the second resin.
- the volume ratio of the aqueous medium is, for example, 50% by volume or more (eg, 50 to 90% by volume) relative to the total volume of the aqueous medium and the second resin.
- the temperature during melt-kneading in the step (A) may be a temperature higher than the melting point or softening point of the second resin, for example, 250° C. or higher (eg, 250 to 350° C.), preferably 260 to 320° C., More preferably, it is 270 to 300°C.
- the melt-kneaded product may be naturally cooled or forcedly cooled, but from the viewpoint of productivity, it is preferable to forcibly cool the melt-kneaded product.
- the cooling rate of the melt-kneaded product is preferably, for example, 1° C./min or more (eg, 1 to 10° C./min).
- hydrophilic solvents used in step (C) include alcohols (ethanol, etc.) and water-soluble ketones (acetone, etc.).
- the temperature and humidity around the precursor particles are adjusted to remove the aqueous medium and adjust the water absorption of the precursor particles. As a result, composite particles can be obtained.
- the thermosetting resin composition according to this embodiment may contain a monofunctional epoxy compound.
- the monofunctional epoxy compounds include monoglycidyl ethers and alkene oxides (eg, octylene oxide, styrene oxide, etc.).
- the monoglycidyl ether examples include alkyl glycidyl ether (eg, 2-ethylhexyl glycidyl ether), alkenyl glycidyl ether (eg, allyl glycidyl ether), aryl glycidyl ether (eg, phenyl glycidyl ether), and the like. mentioned.
- the ratio of the weight of the epoxy resin to the weight of the monofunctional epoxy compound is, for example, 99/1 to 50/50, preferably 97/3 to 60/40. , more preferably 95/5 to 70/30.
- thermosetting resin composition may contain a curing agent.
- the curing agent can be appropriately selected according to the type of the thermosetting resin.
- the curing agent includes, for example, an amine curing agent, a phenolic resin curing agent, an acid anhydride curing agent, a polymercaptan curing agent, and a latent curing agent. .
- amine-based curing agent examples include aromatic amine-based curing agents, aliphatic amine-based curing agents, imidazoles, salts of imidazoles, and alicyclic amine-based curing agents.
- aromatic amine curing agent examples include polyaminoarene, polyamino-alkylarene, poly(aminoalkyl)arene, poly(aminoaryl)alkane, poly(amino-alkylaryl)alkane, and bis(aminoarylalkyl)arene. , di(aminoaryl) ethers (e.g., diaminodiphenyl ether, etc.), di(aminoaryloxy)arenes (e.g., 1,3-bis(3-aminophenoxy)benzene, etc.), di(aminoaryl)sulfones (e.g., diamino diphenylsulfone, etc.).
- di(aminoaryl) ethers e.g., diaminodiphenyl ether, etc.
- di(aminoaryloxy)arenes e.g., 1,3-bis(3-aminophenoxy)benzen
- polyaminoarenes examples include diaminoarenes (eg, paraphenylenediamine, metaphenylenediamine, etc.).
- polyamino-alkylarenes examples include diamino-alkylarenes (eg, diethyltoluenediamine, etc.).
- poly(aminoalkyl)arenes examples include di(aminoalkyl)arenes (eg, xylylenediamine, etc.).
- poly(aminoaryl)alkanes examples include di(aminoaryl)alkanes (eg, diaminodiphenylmethane, etc.).
- poly(amino-alkylaryl)alkanes examples include di(amino-alkylaryl)alkanes (eg, 4,4'-methylenebis(2-ethyl-6-methylaniline) and the like).
- bis(aminoarylalkyl)arene examples include 1,3-bis[2-(4-aminophenyl)-2-propyl)]benzene, 1,4-bis[2-(4-aminophenyl)- 2-propyl)]benzene and the like.
- aliphatic amine curing agent examples include ethylenediamine, hexamethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, and diethylaminopropylamine.
- alicyclic amine curing agent examples include mensenediamine, isophoronediamine, bis(4-amino-3-methylcyclohexyl)methane, 3,9-bis(3-aminopropyl)-2,4,8 , 10-tetraoxaspiro[5.5]undecane, norbornanediamine, and the like.
- Examples of the imidazoles include alkylimidazole, arylimidazole, and the like.
- alkylimidazole examples include 2-methylimidazole, 2-phenylimidazole, 2-heptadecylimidazole, 2-ethyl-4-methylimidazole and the like.
- Examples of the arylimidazole include 2-phenylimidazole, 2-phenyl-4-methylimidazole, 2-phenyl-4-methyl-5-hydroxymethylimidazole, 1-benzyl-2-phenylimidazole and the like.
- imidazole salts examples include salts of imidazoles and formic acid, salts of imidazoles and phenol, salts of imidazoles and phenol novolac, and salts of imidazoles and carbonic acid.
- phenolic resin-based curing agent examples include novolac resins and cresol novolak resins.
- Examples of the acid anhydride curing agent include aliphatic dicarboxylic acid anhydrides, alicyclic dicarboxylic acid anhydrides, and aromatic dicarboxylic acid anhydrides.
- Examples of the aliphatic dicarboxylic anhydride include dodecenyl succinic anhydride.
- Examples of the alicyclic dicarboxylic anhydride include tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, and hexahydrophthalic anhydride.
- Examples of the aromatic dicarboxylic anhydride include phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, and benzophenonetetracarboxylic anhydride.
- latent curing agent examples include boron trifluoride-amine complex, dicyandiamide, and carboxylic acid hydrazide.
- Curing agents may be used alone or in combination of two or more.
- the curing agent may also act as a curing accelerator.
- an amine-based curing agent for example, an aromatic amine-based curing agent is preferable.
- the content ratio of the curing agent can be appropriately selected according to the type of thermosetting resin (epoxy equivalent, etc.) and the type of curing agent. Parts by weight, preferably 1 to 250 parts by weight, more preferably 3 to 200 parts by weight (eg, 4 to 150 parts by weight), particularly preferably 5 to 100 parts by weight.
- the thermosetting resin composition according to this embodiment may contain a curing accelerator.
- the curing accelerator can be appropriately selected according to the type of the thermosetting resin.
- examples of curing accelerators include phosphines, amines, salts of amines, and the like.
- the phosphines include ethylphosphine, propylphosphine, trialkylphosphine, phenylphosphine, and triphenylphosphine.
- the amines include secondary to tertiary amines.
- secondary to tertiary amines examples include triethylamine, piperidine, benzyldimethylamine, triethanolamine, dimethylaminoethanol, triethylenediamine, tris(dimethylaminomethyl)phenol, and N,N-dimethylpiperazine.
- the curing accelerator may be used alone or in combination of two or more.
- the content of the curing accelerator is, for example, 0.01 to 100 parts by weight, preferably 0.05 to 50 parts by weight, and more preferably 1 to 30 parts by weight with respect to 100 parts by weight of the thermosetting resin.
- thermoplastic resin composition according to the present embodiment may further contain at least one of resin particles, a thermoplastic resin and an additive as other components, if necessary.
- polyester particles examples include polyester particles, polyacetal particles, polysulfide particles, polysulfone particles (including polyethersulfone particles), polyetherketone particles, and polyolefin particles.
- polyester particles include aromatic polyester particles (eg, polyethylene terephthalate, etc.).
- thermoplastic resin examples include acrylic resins, polyolefin resins (eg, polypropylene), polyamide resins, polyester resins, polycarbonate resins, polyphenylene ether resins, polyphenylene sulfide resins, polysulfone resins, polyether ketone resins, polyether ether ketones.
- examples include resins, polyimide resins, polyetherimide resins, and the like.
- polyester resin include aromatic polyester resins (eg, polyethylene terephthalate, etc.).
- additives examples include stabilizers, fillers (non-fibrous fillers), colorants, dispersants, preservatives, antioxidants, antifoaming agents, and the like.
- the content of other components is, for example, 10 parts by weight or less (eg, 0.01 to 10 parts by weight) with respect to 100 parts by weight of the thermosetting resin.
- the retention rate of plane strain fracture toughness (K IC ) obtained by the following formula is preferably 85% or more (eg, 85 to 100%), more preferably 90 % or more, and even more preferably 95% or more.
- Retention rate of plane strain fracture toughness (K IC ) (plane strain fracture toughness (K IC ) of a cured product obtained by curing the thermosetting resin composition at 200 ° C.) / (the thermosetting resin composition is 175 K IC of cured product cured at °C) x 100
- the plane strain fracture toughness (K IC ) of a cured product obtained by curing the thermosetting resin composition at 175° C. can be obtained according to ASTM D5045. Specifically, first, the thermosetting resin composition is poured into a mold (47 mm (length) ⁇ 12 mm (width) ⁇ 4 mm (thickness)). Next, the thermosetting resin composition is heated at 175° C. until the thermosetting resin composition is sufficiently cured to obtain a cured product having precracks. In addition, in order to form pre-cracks in the cured product, convex portions corresponding to the pre-cracks are formed on the inner surface of the mold. Next, using the pre-cracked cured product, the plane strain fracture toughness (K IC ) of the cured product obtained by curing the thermosetting resin composition at 175° C. can be determined according to ASTM D5045.
- the plane strain fracture toughness (K IC ) of a cured product obtained by curing the thermosetting resin composition at 200° C. can also be determined according to ASTM D5045. Specifically, in the method for measuring the "plane strain fracture toughness (K IC ) of a cured product obtained by curing a thermosetting resin composition at 175 ° C.”, the heating temperature of 175 ° C. is changed to a heating temperature of 200 ° C. In the same manner as described above, the “plane strain fracture toughness (K IC ) of a cured product obtained by curing a thermosetting resin composition at 200° C.” can be obtained.
- thermoset according to this embodiment is a thermoset obtained by thermosetting the thermosetting resin composition according to this embodiment.
- the shape of the thermoset according to this embodiment may be a one-dimensional shape (such as a rod), a two-dimensional shape (such as a sheet), or a three-dimensional shape.
- the composite particles contain a second resin and an inorganic filler, A thermosetting resin composition, wherein the amount of the inorganic filler in the total amount of the second resin and the inorganic filler is 0.1 to 70% by weight.
- thermosetting resin composition according to item 1 wherein the inorganic filler contains at least one selected from the group consisting of silica, titanium oxide, zinc oxide, bentonite, kaolin, and carbon black.
- thermosetting resin composition according to item 1 or 2 wherein the second resin contains at least one selected from the group consisting of polyamide resins, polyimide resins, and polyethersulfone resins.
- thermosetting resin composition according to any one of items 1 to 3, wherein the composite particles have a median diameter of 1 to 100 ⁇ m.
- thermosetting resin composition according to any one of items 1 to 4, wherein the composite particles have a sphericity of 95% or more.
- thermosetting resin composition according to any one of items 1 to 5, wherein the retention rate of plane strain fracture toughness (K IC ) obtained by the following formula is 85% or more.
- Retention rate of plane strain fracture toughness (K IC ) (plane strain fracture toughness (K IC ) of a cured product obtained by curing the thermosetting resin composition at 200 ° C.) / (the thermosetting resin composition is 175
- thermosetting resin composition according to any one of items 1 to 6, wherein the first resin contains at least one selected from the group consisting of epoxy resins and phenol resins.
- thermosetting resin composition according to any one of items 1 to 7, wherein the composite particles are 1 to 20 parts by weight with respect to 100 parts by weight of the first resin.
- thermoset product obtained by thermosetting the thermosetting resin composition according to any one of items 1 to 8.
- Polyamide 12 (resin for composite particles) Polyamide 12 (PA12): “L1901” manufactured by Daicel-Evonik Polyamide 1010 (PA1010): “DS22” manufactured by Daicel-Evonik Alicyclic polyamide (alicyclic PA): "TROGAMID CX7323” manufactured by Daicel-Evonik
- Epoxy resin (Thermosetting resin) Epoxy resin: "jER828” manufactured by Mitsubishi Chemical Corporation
- Example 1 90 parts by weight of polyamide 12, 10 parts by weight of silica filler (RX50), and polyethylene glycol as an aqueous solvent were melt-kneaded by heating in an extruder and extruded through a die of the extruder to obtain a melt-kneaded product. Next, the melt-kneaded material was forcibly cooled using a spot cooler. Then, using an aspirator and a glass filter, the molten kneaded material was filtered, and the precursor particles remaining on the glass filter were washed with water. Next, the precursor particles were dried at 90° C. for 24 hours using a dehumidifying dryer to obtain composite particles.
- RX50 silica filler
- thermosetting resin composition composite particles: 20% by weight
- thermosetting resin composition (composite particles: 20% by weight) was obtained in the same manner as in Example 1, except that the compounding ratio of the composite particles was set as shown in Table 1 below.
- K IC retention rate K IC of the cured product obtained by curing the thermosetting resin composition at 175° C. and K IC of the cured product obtained by curing the thermosetting resin composition at 200° C. were measured by the method described above. In addition, the retention rate of K IC was determined by the method described above. K IC of the cured product obtained by curing the thermosetting resin composition at 175 ° C. , K IC of the cured product obtained by curing the thermosetting resin composition at 200 ° C., and the retention rate of K IC are shown in Table 1 below. show.
- the reason why the retention rate of K IC was higher in Examples 1 to 6 than in Comparative Example 1 is considered as follows.
- the inorganic filler in the inorganic filler has a smaller linear expansion coefficient than the resin, so even during heat curing at a high temperature of 200 ° C., the inorganic filler has a smaller thermal expansion than the resin, and as a result, the cooling process after heat curing In the inorganic filler, the shrinkage is smaller than that of the resin. From this, it is considered that the cured product of the resin composition containing the composite particles containing the inorganic filler has a small residual stress, and as a result, the toughness of the thermoset product does not easily change even if the curing temperature changes.
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Abstract
Description
硬化温度によって熱硬化物の靭性が変わってしまうと、熱硬化物の表面と内部との間で靭性の差が生じてしまうおそれがある。特に、熱硬化物が大きい場合には、この靭性の差が大きくなってしまうおそれがある。
また、熱硬化物を順次製造する際に、硬化温度に時系列での多少のブレが生じ得るが、このブレにより、最初に得られる熱硬化物と、後で得られる熱硬化物との間で靭性の差が生じてしまうおそれがある。
よって、硬化温度が変わっても熱硬化物の靭性が変化し難い硬化性樹脂組成物と、該硬化性樹脂組成物が熱硬化された熱硬化物とが求められ得る。
前記複合粒子は、第2の樹脂及び無機フィラーを含み、
前記第2の樹脂及び前記無機フィラーの合計量における前記無機フィラーの量が、0.1~70重量%である、熱硬化性樹脂組成物に関する。
好ましくは、前記無機フィラーは、シリカ、酸化チタン、酸化亜鉛、ベントナイト、カオリン、及び、カーボンブラックよりなる群から選択される少なくとも1種を含む。
好ましくは、前記第2の樹脂は、ポリアミド樹脂、ポリイミド樹脂、及び、ポリエーテルスルホン樹脂よりなる群から選択される少なくとも1種を含む。
好ましくは、前記複合粒子のメジアン径が1~100μmである。
好ましくは、前記複合粒子の真球度が95%以上である。
好ましくは、下記式で求められる平面ひずみ破壊靭性(KIC)の保持率が85%以上である。
平面ひずみ破壊靭性(KIC)の保持率 = (前記熱硬化性樹脂組成物が200℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))/(前記熱硬化性樹脂組成物が175℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))×100
好ましくは、前記第1の樹脂は、エポキシ樹脂、及び、フェノール樹脂よりなる群から選択される少なくとも1種を含む。
好ましくは、前記第1の樹脂100重量部に対して、前記複合粒子が1~20重量部である。
また、本明細書に開示された各々の態様は、本明細書に開示された他のいかなる特徴とも組み合わせることができる。
本実施形態に係る熱硬化性樹脂組成物は、熱硬化性樹脂たる第1の樹脂と、複合粒子とを有する。
前記複合粒子は、第2の樹脂及び無機フィラーを含む。
前記第2の樹脂及び前記無機フィラーの合計量における前記無機フィラーの量が、0.1~70重量%である。
前記熱硬化性樹脂たる第1の樹脂としては、例えば、エポキシ樹脂、フェノール樹脂、不飽和ポリエステル樹脂、ビニルエステル樹脂、アクリル樹脂、尿素樹脂、メラミン樹脂、アニリン樹脂、ポリイミド樹脂、ビスマレイミド樹脂などが挙げられる。これらの熱硬化性樹脂は、単独で又は2種以上組み合わせてもよい。
エポキシ樹脂としては、例えば、グリシジルエーテル型エポキシ樹脂、グリシジルアミン型エポキシ樹脂、グリシジルエステル型エポキシ樹脂、アルケンオキシド類(例えば、ビニルシクロヘキセンジオキシドなど)、トリグリシジルイソシアヌレートなどが挙げられる。
前記ビスフェノール類としては、例えば、ビスフェノールA型エポキシ樹脂、ビスフェノールF型エポキシ樹脂、ビスフェノールS型エポキシ樹脂、臭素化ビスフェノール型エポキシ樹脂などが挙げられる。
前記ビスフェノール類のアルキレンオキシド付加体においては、ビスフェノール類のヒドロキシル基1モルに対するアルキレンオキシドの付加モル数は、例えば1モル以上(例えば1~20モル)、好ましくは1~15モル、さらに好ましくは1~10モルである。
前記ナフタレン骨格を有するグリシジルエーテルとしては、例えば、ジ(グリシジルオキシ)ナフタレン、ビス[2,7-ジ(グリシジルオキシ)ナフチル]メタン等が挙げられる。
前記ジ(グリシジルオキシ)ナフタレンとしては、例えば、1,5-ジ(グリシジルオキシ)ナフタレンなどが挙げられる。
前記C2-10アルカンジオールジグリシジルエーテルとしては、例えば、ブタンジオールジグリシジルエーテル、ネオペンチルグリコールジグリシジルエーテル、1,6-ヘキサンジオールジグリシジルエーテル等が挙げられる。
前記ポリC2-4アルカンジオールジグリシジルエーテルとしては、例えば、ポリプロピレングリコールジグリシジルエーテル等が挙げられる。
前記ポリオールとしては、例えば、アルカントリオール、アルカンテトラオール、アルカンペンタオール、アルカンヘキサオール等が挙げられる。前記アルカントリオールとしては、C3-10アルカントリオール等が挙げられる。前記アルカンテトラオールとしては、C3-10アルカンテトラオール等が挙げられる。
前記グリシジルポリエーテルとしては、ジグリシジルエーテル、トリグリシジルエーテル、テトラグリシジルエーテル、ペンタグリシジルエーテル、ヘキサグリシジルエーテル等が挙げられる。
前記ポリオールのグリシジルポリエーテルとしては、例えば、トリメチロールプロパンジグリシジルエーテル、トリメチロールプロパントリグリシジルエーテル、グリセリンジグリシジルエーテル、グリセリントリグリシジルエーテル等が挙げられる。
前記ジカルボン酸としては、例えば、芳香族ジカルボン酸、芳香族ジカルボン酸の水添物等が挙げられる。
前記芳香族ジカルボン酸としては、例えば、テレフタル酸、イソフタル酸、フタル酸、テトラヒドロフタル酸、ヘキサヒドロフタル酸等が挙げられる。
これらのエポキシ樹脂のうち、強度などの点で、芳香族骨格を有するエポキシ樹脂が好ましく、ビスフェノール型エポキシ樹脂が特に好ましい。
前記フェノール樹脂としては、例えば、ノボラック型フェノール樹脂、レゾール型フェノール樹脂、ポリオキシスチレン樹脂などが挙げられる。
前記レゾール型フェノール樹脂は、フェノール類とアルデヒド類と縮合物である。前記レゾール型フェノール樹脂は、例えば、フェノール類とアルデヒド類とをアルカリ性触媒の存在下で縮合重合させることで得られる。
前記クレゾールとしては、o-クレゾール、m-クレゾール、p-クレゾールが挙げられる。
前記トリメチルフェノールとしては、2,3,5-トリメチルフェノール等が挙げられる。
前記キシレノールとしては、2,3-キシレノール、2,4-キシレノール、2,5-キシレノール、3,4-キシレノール、3,5-キシレノール等が挙げられる。
前記ヒドロキシベンズアルデヒドとしては、o-ヒドロキシベンズアルデヒド、m-ヒドロキシベンズアルデヒド、p-ヒドロキシベンズアルデヒドが挙げられる。
40~99重量%、より好ましくは80~97重量%有する。
前記複合粒子は、第2の樹脂及び無機フィラーを含む。
前記ポリアミド樹脂は、ホモポリアミド樹脂又はコポリアミド樹脂であってもよい。
前記ポリアミド樹脂の末端基としては、アミノ基、カルボキシル基、酸無水物基等が挙げられる。
前記脂環族ポリアミドとしては、ジアミン成分及びジカルボン酸成分として、脂環族ジアミン成分及び/又は脂環族ジカルボン酸成分と共に、前記例示の脂肪族ジアミン成分及び/又は脂肪族ジカルボン酸成分を含む脂環族ポリアミド樹脂が好ましい。このような脂環族ポリアミド樹脂は、透明性が高く、いわゆる透明ポリアミドとして知られている。
前記ジアミノシクロアルカンとしては、例えば、ジアミノシクロヘキサン等が挙げられる。前記ジアミノシクロアルカンは、ジアミノC5-10シクロアルカンが好ましい。
前記ビス(アミノシクロアルキル)アルカンとしては、例えば、ビス(4-アミノシクロヘキシル)メタン、ビス(4-アミノ-3-メチルシクロヘキシル)メタン、2,2-ビス(4’-アミノシクロヘキシル)プロパン等が挙げられる。前記ビス(アミノシクロアルキル)アルカンは、ビス(アミノC5-8シクロアルキル)C1-3アルカンが好ましい。
前記脂環族ジアミン成分は、例えば、アルキル基などの置換基を有していてもよい。
該アルキル基は、好ましくはC1-6アルキル基、より好ましくはC1-4アルキル基、さらに好ましくはC1-2アルキル基(メチル基、エチル基等)である。
前記芳香族ポリアミドとしては、構成単位のジアミン成分及び構成単位のジカルボン酸成分の両方が芳香族成分であるポリアミド(「全芳香族ポリアミド」や「アラミド」等とも呼ばれる。)等が挙げられる。
前記芳香族ポリアミドは、変性ポリアミドであってもよい。変性ポリアミドとしては、分岐鎖構造を有するポリアミド等が挙げられる。
前記芳香族ジアミン成分としては、メタキシリレンジアミン等が挙げられる。
前記芳香族ジカルボン酸成分としては、テレフタル酸、イソフタル酸等が挙げられる。また、前記芳香族ジカルボン酸成分は、ダイマー酸等であってもよい。
前記ポリイミド樹脂としては、N,N’-エチレンビスマレイミド、N,N’-ヘキサメチレンビスマレイミド、N,N’-(1,3-フェニレン)ビスマレイミド、N,N’-[1,3-(2-メチルフェニレン)]ビスマレイミド、N,N’-[1,3-(4-メチルフェニレン)]ビスマレイミド、N,N’-(1,4-フェニレン)ビスマレイミド、ビス(4-マレイミドフェニル)メタン、ビス(3-メチル-4-マレイミドフェニル)メタン、3,3-ジメチル-5,5-ジエチル-4,4-ジフェニルメタンビスマレイミド、ビス(4-マレイミドフェニル)エーテル、ビス(4-マレイミドフェニル)スルホン、ビス(4-マレイミドフェニル)スルフィド、ビス(4-マレイミドフェニル)ケトン、ビス(4-マレイミドシクロヘキシル)メタン、1,4-ビス(4-マレイミドフェニル)シクロヘキサン、1,4-ビス(マレイミドメチル)シクロヘキサン、1,4-ビス(マレイミドメチル)ベンゼン、1,3-ビス(4-マレイミドフェノキシ)ベンゼン、1,3-ビス(3-マレイミドフェノキシ)ベンゼン、ビス[4-(3-マレイミドフェノキシ)フェニル]メタン、ビス[4-(4-マレイミドフェノキシ)フェニル]メタン、1,1-ビス[4-(3-マレイミドフェノキシ)フェニル]エタン、1,1-ビス[4-(4-マレイミドフェノキシ)フェニル]エタン、1,2-ビス[4-(3-マレイミドフェノキシ)フェニル]エタン、1,2-ビス[4-(4-マレイミドフェノキシ)フェニル]エタン、2,2-ビス[4-(3-マレイミドフェノキシ)フェニル]プロパン、2,2-ビス[4-(4-マレイミドフェノキシ)フェニル]プロパン、2,2-ビス[4-(3-マレイミドフェノキシ)フェニル]ブタン、2,2-ビス[4-(4-マレイミドフェノキシ)フェニル]ブタン、2,2-ビス[4-(3-マレイミドフェノキシ)フェニル]-1,1,1,3,3,3-ヘキサフルオロプロパン、2,2-ビス[4-(4-マレイミドフェノキシ)フェニル]-1,1,1,3,3,3-ヘキサフルオロプロパン、4,4-ビス(3-マレイミドフェノキシ)ビフェニル、4,4-ビス(4-マレイミドフェノキシ)ビフェニル、ビス[4-(3-マレイミドフェノキシ)フェニル]ケトン、ビス[4-(4-マレイミドフェノキシ)フェニル]ケトン、2,2’-ビス(4-マレイミドフェニル)ジスルフィド、ビス(4-マレイミドフェニル)ジスルフィド、ビス[4-(3-マレイミドフェノキシ)フェニル]スルフィド、ビス[4-(4-マレイミドフェノキシ)フェニル]スルフィド、ビス[4-(3-マレイミドフェノキシ)フェニル]スルホキシド、ビス[4-(4-マレイミドフェノキシ)フェニル]スルホキシド、ビス[4-(3-マレイミドフェノキシ)フェニル]スルホン、ビス[4-(4-マレイミドフェノキシ)フェニル]スルホン、ビス[4-(3-マレイミドフェノキシ)フェニル]エーテル、ビス[4-(4-マレイミドフェノキシ)フェニル]エーテル、1,4-ビス[4-(4-マレイミドフェノキシ)-α,α-ジメチルベンジル]ベンゼン、1,3-ビス[4-(4-マレイミドフェノキシ)-α,α-ジメチルベンジル]ベンゼン、1,4-ビス[4-(3-マレイミドフェノキシ)-α,α-ジメチルベンジル]ベンゼン、1,3-ビス[4-(3-マレイミドフェノキシ)-α,α-ジメチルベンジル]ベンゼン、1,4-ビス[4-(4-マレイミドフェノキシ)-3,5-ジメチル-α,α-ジメチルベンジル]ベンゼン、1,3-ビス[4-(4-マレイミドフェノキシ)-3,5-ジメチル-α,α-ジメチルベンジル]ベンゼン、1,4-ビス[4-(3-マレイミドフェノキシ)-3,5-ジメチル-α,α-ジメチルベンジル]ベンゼン、1,3-ビス[4-(3-マレイミドフェノキシ)-3,5-ジメチル-α,α-ジメチルベンジル]ベンゼン、ポリフェニルメタンマレイミド等が挙げられる。これらのマレイミド化合物は、単独で又は2種以上を組み合わせて用いることができる。
前記第2の樹脂としては、補強効果が大きい点から、半結晶性ポリアミド(例えば、脂環族ポリアミド、脂肪族ポリアミド等)が好ましい。
なお、本実施形態において、数平均分子量は、クロロホルム溶離液を用いたゲルパーミエーションクロマトグラフィー(GPC)を用い、ポリスチレン換算分子量分布より測定されたものをいう。当該GPCにおけるカラムとしては、前記分子量を測定するのに適切なカラムを使用すればよい。
より具体的には、まず、融点を測定するための試料を約5mg用意するとともに、同じ形状で同じ重量の金属(例えば、アルミニウム)製の容器を2つ用意する。
次に、2つの前記容器のうち一方の容器に試料を入れ、他方の容器を空のままとする。
そして、試料を入れた容器と、リファレンスとしての空の容器とをDSCにセットし、窒素ガスを流しながら10℃/minの昇温速度で前記試料を昇温させた際に得られるDSC曲線から融点を求めることができる。
なお、融点は、同一試料に対して2回の示差走査熱量分析を実施して求めることができ、2回目のDSC曲線のピーク値として求められる。
中間点ガラス転移温度は、JIS K7121-1987「プラスチックの転移温度測定方法」に記載されている方法に基づいて求めることができる。
すなわち、まず、中間点ガラス転移温度を測定するための試料を約5mg用意するとともに、同じ形状で同じ重量の金属(例えば、アルミニウム)製の容器を2つ用意する。
次に、2つの前記容器のうち一方の容器に試料を入れ、他方の容器を空のままとする。
そして、試料を入れた容器と、リファレンスとしての空の容器とをDSCにセットし、窒素ガスを流しながら10℃/minの昇温速度で前記試料を昇温させた際に得られるDSC曲線から中間点ガラス転移温度を求めることができる。
本実施形態において、結晶化度は、広角X線回折(WAXD)に基づいて測定できる。
例えば、粉末X線解析ソフトウェア(リガク社製「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、非晶質ハローを分離し、下記式から結晶化度(%)を求めることができる。
結晶化度 = [結晶回折ピークの積分強度総和(cps・deg)]/[結晶回折ピーク及び非晶質ハローの積分強度総和(cps・deg)]×100%
前記無機物としては、シリカ、酸化チタン、酸化亜鉛、ベントナイト、カオリン、カーボンブラックが好ましい。
前記シリカとしては、フュームドシリカ、コロイダルシリカ等が挙げられる。
すなわち、本実施形態において、「無機フィラー」は、「有機ケイ素化合物で表面処理された無機フィラー」を含む概念である。
前記有機ケイ素化合物としては、例えば、ヘキサメチルジシラザン、ジメチルジクロロシラン、オクチルシラン、シリコーンオイル、ジメチルポリシロキサン、アミノシラン、アミノアルキルシラン、メタクリルシラン、アクリルシラン、ビニルシラン、フェニルシラン、メルカプトシラン、エポキシシラン、シランカップリング剤等が挙げられる。
前記無機フィラーのメジアン径は、以下のようにして求めることができる。
まず、無機フィラーを走査電子顕微鏡(SEM)で撮影することにより、画像を得る。
次に、該画像における無機フィラーを無作為に30個以上選択し、選択した各無機フィラーの面積を求める。画像における無機フィラーの個数が30個未満である場合には、各無機フィラーの面積を全て求める。
そして、求めた各面積と同じ面積の真円の直径を、各無機フィラーの直径とする。
次に、求めた無機フィラーの直径の中央値をメジアン径とする。
また、前記無機フィラーのメジアン径は、無機フィラーの個数基準のメジアン径を意味する。
なお、前記無機フィラーについては、1次粒子が複数凝集した2次粒子となって無機フィラーに含まれており、「無機フィラーのメジアン径」は、2次粒子を含めた無機フィラーのメジアン径を意味する。
なお、無機フィラーが「有機ケイ素化合物で表面処理された無機フィラー」を含む場合には、無機フィラーの量には、有機ケイ素化合物の量も含まれる。
前記添加剤としては、例えば、安定剤、着色剤、分散剤、防腐剤、抗酸化剤、消泡剤などが挙げられる。
前記添加剤は、単独で又は2種以上組み合わせてもよい。
前記添加剤の含有割合の合計は、第2の樹脂100重量部に対して、例えば10重量部以下(例えば0.01~10重量部)である。
前記複合粒子のメジアン径は、複合粒子を水に分散させて、レーザー回折/散乱式粒度分布測定装置によって測定した値を意味する。また、前記複合粒子のメジアン径は、複合粒子の体積基準のメジアン径を意味する。
さらに、前記複合粒子のメジアン径は、1次粒子の複合粒子のメジアン径を意味する。
なお、本実施形態において、粒子の真球度は、次の方法により測定できる。すなわち、走査型電子顕微鏡(SEM)で粒子を観察し、無作為に選択した30個の粒子の長径と短径を測定し、各粒子の短径/長径比を求める。そして、短径/長径比の算術平均値を求め、この算術平均値を粒子の真球度とする。なお、粒子の真球度が1に近いほど、粒子が真球であると判断できる。
また、前記複合粒子の吸水率は、例えば、0.01重量%以上であり、好ましくは0.05重量%以上(例えば0.08重量%以上)、好ましくは0.055重量%以上(例えば0.06重量%以上)、さらに好ましくは0.065重量%以上(特に0.07重量%以上)である。
本実施形態に係る熱硬化性樹脂組成物は、複合粒子の吸水率が0.5重量%以上であることにより、靭性が高くなるという利点を有する。
また、本実施形態に係る熱硬化性樹脂組成物は、複合粒子の吸水率が2.5重量%以下であることにより、靭性が高くなるという利点を有する。また、本実施形態に係る熱硬化性樹脂組成物は、複合粒子の吸水率が2.5重量%以下であることにより、複合粒子中にボイドが生じ難くなるという利点を有し得る。
複合粒子の吸水率は、カールフィッシャー法に準拠して測定することができる。
なお、装置としては、水分気化装置((株)三菱化学アナリテック製「型番VA-200」)を備えた微量水分測定装置((株)三菱化学アナリテック製「CA-200」)を用いることができる。
測定温度としては、210℃とすることができる。
複合粒子の製造方法としては、冷凍粉砕法、化学粉砕法、重合法、強制乳化法、レーザー法等が挙げられる。
複合粒子の製造方法としては、強制乳化法が好ましい。
前記水性媒体としては、例えば、熱溶融性の糖類、水溶性高分子などが挙げられる。
前記熱溶融性の糖類としては、例えば、オリゴ糖(例えば、スクロース、マルトトリオースなど)、糖アルコール(例えば、キシリトール、エリスリトール、ソルビトール、マンニトールなど)などが挙げられる。
前記水溶性高分子としては、例えば、水溶性合成高分子(例えば、ポリエチレングリコール、ポリビニルアルコール、ポリアクリル酸ナトリウム、ポリアクリルアミドなど)、多糖類(例えば、デンプン、メチルセルロースなど)などが挙げられる。
これらの水性媒体は、単独で又は二種以上組み合わせて使用できる。
前記水性媒体としては、複合粒子を適度な粒径に調整し易いという観点から、ポリエチレングリコールが好ましい。
水性媒体の体積割合は、水性媒体及び第2の樹脂の総体積に対して、例えば50体積%以上(例えば50~90体積%)である。
溶融混練物の冷却速度は、例えば、1℃/分以上(例えば1~10℃/分)が好ましい。
前記熱硬化性樹脂たる第1の樹脂がエポキシ樹脂を含む場合には、本実施形態に係る熱硬化性樹脂組成物は、単官能性のエポキシ化合物を含んでもよい。
前記単官能性のエポキシ化合物としては、モノグリシジルエーテル、アルケンオキシド(例えば、オクチレンオキシド、スチレンオキシドなど)等が挙げられる。
前記モノグリシジルエーテルとしては、例えば、アルキルグリシジルエーテル(例えば、2-エチルへキシルグリシジルエーテルなど)、アルケニルグリシジルエーテル(例えば、アリルグリシジルエーテルなど)、アリールグリシジルエーテル(例えば、フェニルグリシジルエーテルなど)等が挙げられる。
本実施形態に係る熱硬化性樹脂組成物において、前記単官能性のエポキシ化合物の重量に対する前記エポキシ樹脂の重量の比は、例えば99/1~50/50、好ましくは97/3~60/40、さらに好ましくは95/5~70/30である。
本実施形態に係る熱硬化性樹脂組成物は、硬化剤を含んでもよい。
前記硬化剤としては、前記熱硬化性樹脂の種類に応じて適宜選択できる。
熱硬化性樹脂がエポキシ樹脂である場合の硬化剤としては、例えば、アミン系硬化剤、フェノール樹脂系硬化剤、酸無水物系硬化剤、ポリメルカプタン系硬化剤、潜在性硬化剤などが挙げられる。
前記ポリアミノアレーンとしては、例えば、ジアミノアレーン(例えば、パラフェニレンジアミン、メタフェニレンジアミン等)等が挙げられる。
前記ポリアミノ-アルキルアレーンとしては、例えば、ジアミノ-アルキルアレーン(例えば、ジエチルトルエンジアミン等)等が挙げられる。
前記ポリ(アミノアルキル)アレーンとしては、例えば、ジ(アミノアルキル)アレーン(例えば、キシリレンジアミン等)等が挙げられる。
前記ポリ(アミノアリール)アルカンとしては、例えば、ジ(アミノアリール)アルカン(例えば、ジアミノジフェニルメタン等)等が挙げられる。
前記ポリ(アミノ-アルキルアリール)アルカンとしては、例えば、ジ(アミノ-アルキルアリール)アルカン(例えば、4,4’-メチレンビス(2-エチル-6-メチルアニリン)等)等が挙げられる。
前記ビス(アミノアリールアルキル)アレーンとしては、例えば、1,3-ビス[2-(4-アミノフェニル)-2-プロピル)]ベンゼン、1,4-ビス[2-(4-アミノフェニル)-2-プロピル)]ベンゼン等が挙げられる。
前記アルキルイミダゾールとしては、例えば、2-メチルイミダゾール、2-フェニルイミダゾール、2-へプタデシルイミダゾール、2-エチル-4-メチルイミダゾール等が挙げられる。
前記アリールイミダゾールとしては、例えば、2-フェニルイミダゾール、2-フェニル-4-メチルイミダゾール、2-フェニル-4-メチル-5-ヒドロキシメチルイミダゾール、1-ベンジル-2-フェニルイミダゾール等が挙げられる。
前記脂肪族ジカルボン酸無水物としては、例えば、ドデセニル無水コハク酸などが挙げられる。
前記脂環族ジカルボン酸無水物としては、例えば、テトラヒドロ無水フタル酸、メチルテトラヒドロ無水フタル酸、ヘキサヒドロ無水フタル酸などが挙げられる。
前記芳香族ジカルボン酸無水物としては、例えば、無水フタル酸、無水トリメリット酸、無水ピロメリット酸、ベンゾフェノンテトラカルボン酸無水物などが挙げられる。
前記硬化剤としては、アミン系硬化剤(例えば、芳香族アミン系硬化剤)が好ましい。
本実施形態に係る熱硬化性樹脂組成物は、硬化促進剤を含んでもよい。
前記硬化促進剤としては、前記熱硬化性樹脂の種類に応じて適宜選択できる。
熱硬化性樹脂がエポキシ樹脂である場合の硬化促進剤としては、例えば、ホスフィン類、アミン類、アミン類の塩などが挙げられる。
前記ホスフィン類としては、例えば、エチルホスフィン、プロピルホスフィン、トリアルキルホスフィン、フェニルホスフィン、トリフェニルホスフィンなどが挙げられる。
前記アミン類としては、例えば、第2~3級アミン類等が挙げられる。
第2~3級アミン類としては、例えば、トリエチルアミン、ピペリジン、ベンジルジメチルアミン、トリエタノールアミン、ジメチルアミノエタノール、トリエチレンジアミン、トリス(ジメチルアミノメチル)フェノール、N,N-ジメチルピペラジン等が挙げられる。
硬化促進剤は、単独で又は2種以上組み合わせてもよい。
本実施形態に係る熱可塑性樹脂組成物は、必要に応じて、他の成分として、樹脂粒子、熱可塑性樹脂及び添加剤の少なくとも何れか一をさらに含んでいてもよい。
前記ポリエステル粒子としては、例えば、芳香族ポリエステル粒子(例えば、ポリエチレンテレフタレート等)等が挙げられる。
前記ポリエステル樹脂としては、例えば、芳香族ポリエステル樹脂(例えば、ポリエチレンテレフタレートなど)などが挙げられる。
平面ひずみ破壊靭性(KIC)の保持率 = (前記熱硬化性樹脂組成物が200℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))/(前記熱硬化性樹脂組成物が175℃で硬化された硬化物のKIC)×100
具体的には、まず、熱硬化性樹脂組成物を金型(47mm(長さ)×12mm(幅)×4mm(厚み))に流し込む。次に、熱硬化性樹脂組成物が十分に硬化するまで熱硬化性樹脂組成物を175℃で加熱し、予亀裂を有する硬化物を得る。
なお、該硬化物に予亀裂を設けるべく、前記金型の内面には、前記予亀裂に対応する凸部が形成されている。
次に、予亀裂を有する硬化物を用いて、熱硬化性樹脂組成物が175℃で硬化された硬化物の平面ひずみ破壊靭性(KIC)をASTM D5045に準拠して求めることができる。
具体的には、上記「熱硬化性樹脂組成物が175℃で硬化された硬化物の平面ひずみ破壊靭性(KIC)」の測定方法において、175℃の加熱温度を200℃の加熱温度に変えること以外は同様にして、「熱硬化性樹脂組成物が200℃で硬化された硬化物の平面ひずみ破壊靭性(KIC)」を求めることができる。
本実施形態に係る熱硬化物の形状は、一次元的形状(棒状など)、二次元的形状(シート状など)、又は、三次元的形状であってもよい。
以下の項目のそれぞれは、好ましい実施形態の開示である。
熱硬化性樹脂たる第1の樹脂と、複合粒子とを有し、
前記複合粒子は、第2の樹脂及び無機フィラーを含み、
前記第2の樹脂及び前記無機フィラーの合計量における前記無機フィラーの量が、0.1~70重量%である、熱硬化性樹脂組成物。
前記無機フィラーは、シリカ、酸化チタン、酸化亜鉛、ベントナイト、カオリン、及び、カーボンブラックよりなる群から選択される少なくとも1種を含む、項目1に記載の熱硬化性樹脂組成物。
前記第2の樹脂は、ポリアミド樹脂、ポリイミド樹脂、及び、ポリエーテルスルホン樹脂よりなる群から選択される少なくとも1種を含む、項目1又は2に記載の熱硬化性樹脂組成物。
前記複合粒子のメジアン径が1~100μmである、項目1~3の何れか1項に記載の熱硬化性樹脂組成物。
前記複合粒子の真球度が95%以上である、項目1~4の何れか1項に記載の熱硬化性樹脂組成物。
下記式で求められる平面ひずみ破壊靭性(KIC)の保持率が85%以上である、項目1~5の何れか1項に記載の熱硬化性樹脂組成物。
平面ひずみ破壊靭性(KIC)の保持率 = (前記熱硬化性樹脂組成物が200℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))/(前記熱硬化性樹脂組成物が175℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))×100
前記第1の樹脂は、エポキシ樹脂、及び、フェノール樹脂よりなる群から選択される少なくとも1種を含む、項目1~6の何れか1項に記載の熱硬化性樹脂組成物。
前記第1の樹脂100重量部に対して、前記複合粒子が1~20重量部である、項目1~7の何れか1項に記載の熱硬化性樹脂組成物。
項目1~8の何れか1項に記載の熱硬化性樹脂組成物が熱硬化された、熱硬化物。
ポリアミド12(PA12):ダイセル・エボニック社製の「L1901」
ポリアミド1010(PA1010):ダイセル・エボニック社製の「DS22」
脂環族ポリアミド(脂環族PA):ダイセル・エボニック社製の「トロガミドCX7323」
シリカフィラー(ヘキサメチルジシラザンで表面処理されたフュームドシリカ)(疎水性フュームドシリカ):アエロジル社製の「RX50」
シリカフィラー(ジメチルジクロロシランで表面処理されたフュームドシリカ)(疎水性フュームドシリカ):アエロジル社製の「R972V」
エポキシ樹脂:三菱化学社製の「jER828」
アミン系硬化剤:三菱化学社製の「jERキュアW」
90重量部のポリアミド12と、10重量部のシリカフィラー(RX50)と、水性溶媒たるポリエチレングリコールとを押出機で加熱により溶融混練し、押出機のダイから押し出し、溶融混練物を得た。
次に、スポットクーラーを用いて前記溶融混練物を強制的に冷却した。
そして、アスピレーターとグラスフィルターとを用いて、前記溶融混練物を濾過しつつ、グラスフィルターに留まった前駆体粒子を水で洗浄した。
次に、除湿乾燥機を用いて前駆体粒子を90℃で24時間乾燥させ、複合粒子を得た。実施例1における複合粒子の断面のSEM写真を図1に示す。
次に、ホットスターラーを用いて、80℃、300rpmの条件下で、前記エポキシ樹脂及び前記複合粒子を6時間撹拌することにより混合物を得た。
そして、該混合物を真空容器中で1時間放置することにより、該混合物を脱泡させた。
次に、脱泡した混合物に硬化剤を加えて撹拌および脱泡を行うことにより、熱硬化性樹脂組成物(複合粒子:20重量%)を得た。
複合粒子の配合割合を下記表1のようにしたこと以外は、実施例1と同様にして熱硬化性樹脂組成物(複合粒子:20重量%)を得た。
複合粒子のメジアン径及び真球度は、上述した方法で測定した。
複合粒子のメジアン径及び真球度を下記表1に示す。
熱硬化性樹脂組成物が175℃で硬化された硬化物のKIC、及び、熱硬化性樹脂組成物が200℃で硬化された硬化物のKICは、上述した方法で測定した。
また、KICの保持率は、上述した方法で求めた。
熱硬化性樹脂組成物が175℃で硬化された硬化物のKIC、熱硬化性樹脂組成物が200℃で硬化された硬化物のKIC、及び、KICの保持率を下記表1に示す。
従って、本開示によれば、硬化温度が変わっても熱硬化物の靭性が変化し難い硬化性樹脂組成物を提供し得ることがわかる。
無機フィラーにおける無機物は、樹脂に比べて線膨張係数が小さいので、200℃といった高温での熱硬化時においても、無機フィラーでは樹脂に比べて熱膨張が小さく、その結果、熱硬化後の冷却過程において、無機フィラーでは樹脂に比べて収縮も小さくなる。
このことから、無機フィラーを含む複合粒子が含有された樹脂組成物の硬化物では、残留応力が小さくなり、その結果、硬化温度が変わっても熱硬化物の靭性が変化し難くなると考えられる。
Claims (9)
- 熱硬化性樹脂たる第1の樹脂と、複合粒子とを有し、
前記複合粒子は、第2の樹脂及び無機フィラーを含み、
前記第2の樹脂及び前記無機フィラーの合計量における前記無機フィラーの量が、0.1~70重量%である、熱硬化性樹脂組成物。 - 前記無機フィラーは、シリカ、酸化チタン、酸化亜鉛、ベントナイト、カオリン、及び、カーボンブラックよりなる群から選択される少なくとも1種を含む、請求項1に記載の熱硬化性樹脂組成物。
- 前記第2の樹脂は、ポリアミド樹脂、ポリイミド樹脂、及び、ポリエーテルスルホン樹脂よりなる群から選択される少なくとも1種を含む、請求項1又は2に記載の熱硬化性樹脂組成物。
- 前記複合粒子のメジアン径が1~100μmである、請求項1又は2に記載の熱硬化性樹脂組成物。
- 前記複合粒子の真球度が95%以上である、請求項1又は2に記載の熱硬化性樹脂組成物。
- 下記式で求められる平面ひずみ破壊靭性(KIC)の保持率が85%以上である、請求項1又は2に記載の熱硬化性樹脂組成物。
平面ひずみ破壊靭性(KIC)の保持率 = (前記熱硬化性樹脂組成物が200℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))/(前記熱硬化性樹脂組成物が175℃で硬化された硬化物の平面ひずみ破壊靭性(KIC))×100 - 前記第1の樹脂は、エポキシ樹脂、及び、フェノール樹脂よりなる群から選択される少なくとも1種を含む、請求項1又は2に記載の熱硬化性樹脂組成物。
- 前記第1の樹脂100重量部に対して、前記複合粒子が1~20重量部である、請求項1又は2に記載の熱硬化性樹脂組成物。
- 請求項1又は2に記載の熱硬化性樹脂組成物が熱硬化された、熱硬化物。
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JPH01165650A (ja) * | 1987-12-23 | 1989-06-29 | Sumitomo Bakelite Co Ltd | エポキシ樹脂組成物 |
JPH01172447A (ja) * | 1987-12-28 | 1989-07-07 | Sumitomo Bakelite Co Ltd | エポキシ樹脂組成物 |
JPH11236455A (ja) * | 1998-02-20 | 1999-08-31 | Dainippon Ink & Chem Inc | エポキシ樹脂複合材料の製造方法 |
JP2010270197A (ja) * | 2009-05-20 | 2010-12-02 | Citizen Electronics Co Ltd | コーティング用樹脂組成物および該組成物を用いて得られる硬化体 |
WO2018016138A1 (ja) | 2016-07-19 | 2018-01-25 | ダイセル・エボニック株式会社 | ポリアミド粒子及びその製造方法、樹脂組成物並びに成形品 |
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JPH01165650A (ja) * | 1987-12-23 | 1989-06-29 | Sumitomo Bakelite Co Ltd | エポキシ樹脂組成物 |
JPH01172447A (ja) * | 1987-12-28 | 1989-07-07 | Sumitomo Bakelite Co Ltd | エポキシ樹脂組成物 |
JPH11236455A (ja) * | 1998-02-20 | 1999-08-31 | Dainippon Ink & Chem Inc | エポキシ樹脂複合材料の製造方法 |
JP2010270197A (ja) * | 2009-05-20 | 2010-12-02 | Citizen Electronics Co Ltd | コーティング用樹脂組成物および該組成物を用いて得られる硬化体 |
WO2018016138A1 (ja) | 2016-07-19 | 2018-01-25 | ダイセル・エボニック株式会社 | ポリアミド粒子及びその製造方法、樹脂組成物並びに成形品 |
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