Back to results
US 2021/0108042 A1Published application
Fiber-reinforced resin prepreg, molded article, and fiber-reinforced thermoplastic resin prepreg
AssigneeMitsubishi Chemical Corporation
InventorsTakahiro HAYASHI, Naoki SUGIURA, Masayasu HASUIKE
Life of this patent
Estimating the term…
Abstract
A fiber-reinforced resin prepreg and a molded article obtained by molding a molding material including the fiber-reinforced resin prepreg are described. The fiber-reinforced resin prepreg contains a carbon fiber bundle and a matrix resin composition. The ipa value of the carbon fiber bundle measured by an electrochemical measurement method is 0.14 μA/cm2 or more. The impact strength of a film obtained by solidifying the matrix resin composition under particular molding conditions is 12.0 kJ/m or more.
Claims20
1:
- A fiber-reinforced resin prepreg, comprising:
- a carbon fiber bundle;
- and
- a matrix resin composition,
- wherein an ipa value of the carbon fiber bundle measured by cyclic voltammetry is 0.14 μA/cm2 or more, and
- the matrix resin composition satisfies Condition 1 specified below,
- Condition 1:
- an impact strength of a film obtained by solidifying the matrix resin composition under Molding Conditions specified below is 12.0 kJ/m or more, and the impact strength is measured using Impact Test specified below,
- Molding Conditions:
- the matrix resin composition is extruded and drawn at a draw ratio gf 1.1 times, and brought into contact for three seconds with a roll temperature-controlled to a temperature of (Tm −125°) C in a case where a crystal melting enthalpy ΔHm of the matrix resin composition is 10 J/g or more, or to a temperature of (Tg −30°) C in a case where the crystal melting enthalpy ΔHm of the matrix resin composition is less than 10 J/g, thereby obtaining a film having a thickness of 40 to 60 μm, where Tg and Tm are respectively a glass transition temperature and a melting point measured using differential scanning calorimetry in accordance with ISO11357,
- Impact Test:
- a test piece of 100 mm in length and 100 mm in width is cut out of the film, the test piece is fixed with a clamp, a striking core with a ½ inch diameter is dropped at a falling speed of 3 m/sec on a center of the test piece at a temperature of 23° C. to apply an impact thereto, and impact absorption energy when the test piece is fractured is measured and divided by the film thickness to obtain the impact strength of the film.
9 more elements
2:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition is a thermoplastic resin composition.
3:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein an average roughness Ra of a surface of single fibers constituting the carbon fiber bundle is 1.0 nm or more and 4.0 nm or less.
4:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the ipa value of the carbon fiber bundle is 0.14 μA/cm2 or more and 0.20 μA/cm2 or less.
5:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein O1S/C1S, which is a quantity of oxygen-containing functional groups on a surface of the carbon fiber bundle measured by X-ray photoelectron spectroscopy, is 0.070 or more and 0.130 or less;
- and N1S/C1S, which is a quantity of nitrogen-containing functional groups on the surface of the carbon fiber bundle measured by X-ray photoelectron spectroscopy, is 0.065 or more and 0.100 or less.
6:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein a strand strength of the carbon fiber bundle is 5600 MPa or more and a strand elastic modulus of the carbon fiber bundle is 250 GPa or more and 380 GPa or less.
7:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition satisfies Condition 2 specified below,
- Condition 2:
- the impact strength of the film is 12.0 kJ/m or more and 20.0 kJ/m or less.
1 more element
8:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the carbon fiber bundle is included in a carbon fiber base material and is oriented unidirectionally.
9:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition satisfies Condition 3 specified below,
- Condition 3:
- when the matrix resin composition is drawn the draw ratio gf 1.1 times and is made into the film having a thickness of 40 to 60 μm, a tear strength of the film measured by a method specified in JIS K7128 (C method) in both a MD direction and a TD direction is 1200 N/mm or more.
1 more element
10:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition contains a polyarylketone resin having a branched structure.
11:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition contains a polyarylketone resin having a melt volume rate of 1 to 80 cm3/10 min, the melt volume rate being measured according to ISO1133 at a set temperature of 380° C. and a load of 5 kg.
12:
- The fiber-reinforced resin prepreg according to claim 1,
- wherein the matrix resin composition contains a polyarylketone resin and a polyetheretherketone resin having a structural unit represented by Formula (4):
13:
- A molded article obtained by a process comprising:
- molding a molding material including the fiber-reinforced resin prepreg according to claim 1.
14:
- The fiber-reinforced resin prepreg according to claim 3,
- wherein O1S/C1S, which a quantity of oxygen-containing functional groups on a surface of the carbon fiber bundle measured by X-ray photoelectron spectroscopy, is 0.070 or more and 0.130 or less;
- and N1S/C1S, which is a quantity of nitrogen-containing functional groups on the surface of the carbon fiber bundle measured by X-ray photoelectron spectroscopy, is 0.065 or more and 0.100 or less.
15:
- A fiber-reinforced thermoplastic resin prepreg, comprising:
- a matrix resin composition, and
- a carbon fiber base material including a carbon fiber bundle,
- wherein the matrix resin composition is impregnated in the carbon fiber base material,
- an average roughness Ra of a surface of single fibers constituting the carbon fiber bundle included in the carbon fiber base material is 1.0 to 4.0 nm,
- an ipa value of the carbon fiber bundle measured by cyclic voltammetry is 0.14 to 0.20 μA/cm2, and
- the matrix resin composition is a thermoplastic resin composition having an impact absorption energy of 0.7 J or more measured using Impact Test specified below,
- Impact Test:
- a test piece of 100 mm in length and 100 mm in width is cut out gf a film having a thickness of 100 μm formed using the matrix resin composition, the test piece is fixed with a clamp, a striking core with a ½ inch diameter is dropped at a falling speed of 3 m/sec on a center of the test at a temperature of 23° C. to apply an impact thereto, and impact absorption energy when the test piece is fractured is measured.
6 more elements
16:
- A method for producing a fiber-reinforced resin prepreg, the method comprising:
- impregnating a carbon fiber bundle with a matrix resin composition,
- wherein an ipa value of the carbon fiber bundle measured by cyclic voltammetry is 0.14 μA/cm2 or more, and
- the matrix resin composition satisfies Condition 1 specified below,
- Condition 1:
- an impact strength of a film obtained by solidifying the matrix resin composition under Molding Conditions specified below is 12.0 kJ/m or more, and the impact strength is measured using Impact Test specified below,
- Molding Conditions:
- the matrix resin composition is extruded and drawn at a draw ratio gf 1.1 times, and brought into contact for three seconds with a roll temperature-controlled to a temperature of (Tm −125°) C in a case where a crystal melting enthalpy ΔHm of the matrix resin composition is 10 J/g or more, or to a temperature of (Tg −30°) C in a case where the crystal melting enthalpy ΔHm of the matrix resin composition is less than 10 J/g, thereby obtaining a film having a thickness of 40 to 60 μm, where Tg and Tm are respectively a glass transition temperature and a melting point measured using differential scanning calorimetry in accordance with ISO11357,
- Impact Test:
- a test piece of 100 mm in length and 100 mm in width is cut out of the film, the test piece is fixed with a clamp, a striking core with a ½ inch diameter is dropped at a falling speed of 3 m/sec on a center of the test piece at a temperature of 23° C. to apply an impact thereto, and impact absorption energy when the test piece is fractured is measured and divided by the film thickness to obtain the impact strength of the film.
7 more elements
17:
- The method according to claim 16,
- wherein the matrix resin composition contains a polyarylketone resin and a polyetheretherketone resin having a structural unit represented by Formula (4):
18:
- The method according to claim 16,
- wherein the carbon fiber bundle is included in a carbon fiber base material and is oriented unidirectionally.
19:
- The method according to claim 16,
- wherein an average unevenness Ra of a surface of single fibers constituting the carbon fiber bundle is 1.0 nm or more and 4.0 nm or less.
20:
- The fiber-reinforced resin prepreg according to claim 11,
- wherein the matrix resin composition contains a polyarylketone resin and a polyetheretherketone resin having a structural unit represented by Formula (4):