Fiber reinforced polyamide resin material

Patent metadata

Field	Value
Publication number	US-10077335-B2
Application number	US-201314429486-A
Country	US
Kind code	B2
Filing date	Aug 1, 2013
Priority date	Sep 25, 2012
Publication date	Sep 18, 2018
Grant date	Sep 18, 2018

Abstract

Provided is a fiber reinforced polyamide resin material which has high rigidity and low water absorbency, and is excellent in moldability and mechanical properties of the molded article. A fiber reinforced polyamide resin material, comprises 100 parts by mass of polyamide resin (A) which is a polycondensate of diamine and dicarboxylic acid and 5 to 300 parts by mass of a carbon fiber (B); wherein 70 mol % or more of the diamine is a xylylenediamine; 50 mol % or more the dicarboxylic acid is a Straight-chain aliphatic dicarboxylic acid containing 4 to 20 carbon atoms; the polyamide resin (A) has a terminal amino group concentration ([NH 2 ]) (in μeq/g) of 5<[NH 2 ]<150; and the carbon fiber (B) has on a surface thereof a compound (C) which is reactive with amino group.

First claim

The invention claimed is:

1. A fiber reinforced polyamide resin material, comprising 100 parts by mass of polyamide resin (A) which is a polycondensate of diamine and dicarboxylic acid and 5 to 300 parts by mass of a carbon fiber (B);
wherein 70 mol % or more of the diamine is a xylylenediamine;
50 mol % or more of the dicarboxylic acid is a straight-chain aliphatic dicarboxylic acid containing 4 to 20 carbon atoms;
the polyamide resin (A) has a terminal amino group concentration ([NH 2 ]) (in μeq/g) of 70<[NH 2 ]<150 (in μeq/g);
the polyamide resin (A) has a terminal carboxy group concentration ([COOH]) of 20<[COOH]<50 (in μeq/g);
the polyamide resin (A) satisfies [NH 2 ]/[COOH]≥1.40; and
the carbon fiber (B) has on a surface thereof a compound (C) which is reactive with an amino group and is treated in an amount of 1.4% by mass or less of the carbon fiber (B), the compound (C) comprising an epoxy compound having 1 to 4 of epoxy groups,
wherein the polyamide resin has a rate of semi-crystallization of 17 seconds or less at 140° C., a rate of impregnation of the polyamide resin (A) in the carbon fiber (B) of 70% or more, and an interfacial shear strength between the polyamide resin (A) and the carbon fiber (B) of 33 MPa or more.

2. The fiber reinforced polyamide resin material of claim 1 ,
wherein the xylylenediamine is meta-xylylenediamine, para-xylylenediamine or a mixture of meta-xylylenediamine and para-xylylenediamine.

3. The fiber reinforced polyamide resin material of claim 1 ,
wherein the straight-chain aliphatic dicarboxylic acid is adipic acid, sebacic acid or a mixture of adipic acid and sebacic acid.

4. The fiber reinforced polyamide resin material of claim 1 , wherein 50 mol % or more of a dicarboxylic acid constitutive unit is derived from sebacic acid.

5. The fiber reinforced polyamide resin material of claim 1 ,
wherein 80 mol % or more of a diamine constitutive unit is derived from xylylenediamine and 30 mol % or more of a diamine constitutive unit is derived from para-xylylenediamine.

6. The fiber reinforced polyamide resin material of claim 1 , wherein the reactive functional group is a carboxy group and an amino group.

7. The fiber reinforced polyamide resin material of claim 1 ,
wherein the compound (C) which is reactive with an amino group further comprises at least one species selected from the group consisting of bisphenol A-glycidyl ether, bisphenol F-glycidyl ether and tolylene diisocyanate.

8. The fiber reinforced polyamide resin material of claim 1 ,
wherein the compound (C) which is reactive with an amino group further comprises at least one species selected from the group consisting of a dicyanate adduct of bisphenol A and an alkylene oxide adduct diglycidyl ether of bisphenol F.

9. The fiber reinforced polyamide resin material of claim 1 ,
wherein the polyamide resin (A) has a relative viscosity of 1.3 to 3.3.

10. The fiber reinforced polyamide resin material of claim 1 , which satisfies a interfacial shear strength between the polyamide resin (A) and the carbon fiber (B), measured by the micro-droplet method, of 40 MPa or larger.

11. The fiber reinforced polyamide resin material of claim 1 ,
wherein the polyamide resin (A) has a number-average molecular weight of 50,000 or smaller.

12. The fiber reinforced polyamide resin material of claim 1 , having at least one bond formed between the compound (C) which is reactive with an amino group and amino group(s) contained in the polyamide resin (A).

13. A material obtained by kneading a fiber reinforced polyamide resin material described in claim 1 .

14. A molded article obtained by molding a fiber reinforced polyamide resin material described in claim 1 .

15. A method for manufacturing a molded article, the method comprising pressing a fiber reinforced polyamide resin material described in claim 1 , for 1 to 60 minutes.

16. The fiber reinforced polyamide resin material described in claim 12 , which is in a form of cloth or tape.

17. The fiber reinforced polyamide resin material of claim 1 ,
wherein the polyamide resin (A) has a concentration of a reactive functional group of 40 μeq/g or more; and
the compound (C) which is reactive with an amino group is treated in an amount of 1.4% by mass or less of the carbon fiber (B).

18. The fiber reinforced polyamide resin material of claim 1 , wherein the polyamide resin has a rate of semi-crystallization of 17 seconds or less at 140° C.

19. The method for manufacturing a molded article of claim 15 , wherein pressing a fiber reinforced polyamide resin material is carried out within 1 to 10 minutes.

20. The fiber reinforced polyamide resin material of claim 1 , wherein the polyamide resin (A) has a terminal amino group concentration ([NH 2 ]) (in μeq/g) of 80<[NH 2 ]<150 (in μeq/g).

21. The fiber reinforced polyamide resin material of claim 1 , wherein the fiber reinforced polyamide resin material substantially does not include a polyamide resin other than polyamide resin (A).

22. The fiber reinforced polyamide resin material of claim 1 , wherein the fiber reinforced polyamide resin material is free from a copper compound.

23. The fiber reinforced polyamide resin material of claim 1 , wherein the carbon fiber (B) has an average fiber diameter of 1 to 10 μm.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Matsumoto Nobuhiko
• Mitadera Jun

Classifications

• C08K7/06

  Elements · CPC title

• C08G69/48 Primary

  Polymers modified by chemical after-treatment · CPC title

• C08J5/06 Primary

  using pretreated fibrous materials · CPC title

• C08J2377/06

  Polyamides derived from polyamines and polycarboxylic acids (C08J2377/10 takes precedence) · CPC title

• C08L77/06

  Polyamides derived from polyamines and polycarboxylic acids (C08L77/10 takes precedence) · CPC title