Method for producing composite material and composite material

Patent metadata

Field	Value
Publication number	US-10597500-B2
Application number	US-201716317922-A
Country	US
Kind code	B2
Filing date	Jul 13, 2017
Priority date	Jul 15, 2016
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

An object of the invention is achieved by a method for producing a composite material, including the steps of combining a resin precursor and a reinforcing fiber and carrying out a polymerization reaction of the resin precursor. That is, a thermoplastic resin composite material having high strength can be obtained by the production method.

First claim

The invention claimed is:

1. A method for producing a composite material, comprising:
combining a solid resin precursor and a reinforcing fiber; and
polycondensing the resin precursor with pressing under vacuum of a degree of vacuum of 0.005 MPa or less.

2. The method for producing the composite material according to claim 1 , wherein the resin precursor is an oligomer of a thermoplastic resin.

3. The method for producing the composite material according to claim 1 , wherein the resin precursor has a viscosity of from 1 to 100 Pa·s, the viscosity being measured by using a capillary rheometer under conditions of a temperature of 220° C. and a shear velocity of 1200 s −1 .

4. The method for producing the composite material according to claim 1 , wherein the resin precursor comprises at least one selected from the group consisting of polyamide, polyester, polycarbonate, polyether, polysulfide and ketone-based resin.

5. The method for producing the composite material according to claim 1 , wherein the reinforcing fiber comprises at least one selected from the group consisting of glass fiber, carbon fiber, basalt fiber, SiC fiber, and organic fiber.

6. The method for producing the composite material according to claim 1 , wherein a proportion of the reinforcing fiber in the composite material is from 1 to 90 vol %.

7. The method for producing the composite material according to claim 1 , wherein the reinforcing fiber is a discontinuous fiber material.

8. The method for producing the composite material according to claim 7 , wherein the discontinuous fiber material comprises at least one selected from the group consisting of a roving, a non-woven fabric, and a tape.

9. The method for producing the composite material according to claim 7 , wherein the discontinuous fiber material has a fiber length of from 0.5 mm to 100 mm.

10. The method for producing the composite material according to claim 1 , wherein the reinforcing fiber is a continuous fiber material.

11. The method for producing the composite material according to claim 10 , wherein the continuous fiber material is unidirectional fiber, a woven fabric, a knitted fabric, or a braided fabric.

12. The method for producing the composite material according to claim 1 , wherein the combining is performed by any one of an immersion process, an impregnation process, and a kneading process.

13. The method for producing the composite material according to claim 1 , wherein a reaction temperature in the polycondensing is from 100° C. to 400° C.

14. The method for producing the composite material according to claim 1 , wherein a pressure of the pressing is from 0.1 to 30 MPa.

15. The method for producing the composite material according to claim 1 , wherein in the polycondensing, pressing is simultaneously performed.

16. The method for producing the composite material according to claim 15 , wherein the pressing is performed by a vacuum pressing process.

17. The method for producing the composite material according to claim 16 , wherein a pressure of the vacuum pressing process is from 0.1 to 30 MPa.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Horie Shigeru
• Matsumoto Nobuhiko
• Ikeuchi Kousuke
• Someya Masao

Classifications

• C08J5/04 Primary

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• C08G69/28

  Preparatory processes · CPC title

• B29K2995/0094

  Geometrical properties · CPC title

• C08G69/04

  Preparatory processes · CPC title

• B29C70/48

  and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} · CPC title