Member for composite material, composite material, mobile body, and method for manufacturing film for composite material

Patent metadata

Field	Value
Publication number	US-12398252-B2
Application number	US-202217848586-A
Country	US
Kind code	B2
Filing date	Jun 24, 2022
Priority date	Dec 27, 2019
Publication date	Aug 26, 2025
Grant date	Aug 26, 2025

Abstract

The following is provided as a member for a composite material that has excellent durability, impact resistance, and productivity. A member for a composite material containing a resin component that contains polyaryletherketone as a main component. The resin component has a molecular weight distribution of 2 or more and less than 4 and a mass average molecular weight of 63000 or more. The composite material contains a resin and reinforcing fibers having a number average fiber length of 5 mm or more.

First claim

The invention claimed is:

1. A multilayer body comprising:
a first layer comprising a resin containing polyaryletherketone as a main component, and a second layer comprising reinforcing fibers having a number average fiber length of 5 mm or more,
wherein the resin has a molecular weight distribution of 2 or more and less than 4 and a mass average molecular weight of 63000 or more.

2. The multilayer body according to claim 1 ,
wherein the polyaryletherketone comprises polyetheretherketone.

3. The multilayer body according to claim 1 ,
wherein a percentage of a content of the polyaryletherketone in the resin is more than 90 mass %.

4. The multilayer body according to claim 1 ,
wherein the resin has the mass average molecular weight of 150000 or less.

5. The multilayer body according to claim 1 ,
wherein the polyaryletherketone has the molecular weight distribution of 2 or more and less than 4 and the mass average molecular weight of 63000 or more.

6. The multilayer body according to claim 1 ,
wherein the polyaryletherketone has the mass average molecular weight of 150000 or less.

7. The multilayer body according to claim 1 ,
wherein the first layer has a crystal heat of fusion of 30 J/g or more and 45 J/g or less.

8. The multilayer body according to claim 1 ,
wherein the first layer has a number of times of folding endurance of 5000 or more when measured under conditions of: a thickness of 100 μm, a folding angle of 135°, a folding speed of 175 cpm, and a load of 9.8 N.

9. The multilayer body according to claim 1 ,
wherein a puncture impact strength of the first layer is 0.3 J or more when measured under conditions of: a thickness of 100 μm, 23° C., a fixing frame inner diameter of 50 mm, a punching striker diameter of 12.7 mm, and a test speed of 3 m/second.

10. The multilayer body according to claim 1 ,
wherein a puncture impact strength of the first layer is 0.3 J or more when measured under conditions of: a thickness of 100 μm, −20° C., a fixing frame inner diameter of 50 mm, a punching striker diameter of 12.7 mm, and a test speed of 3 m/second.

11. The multilayer body according to claim 1 ,
wherein the first layer has a thickness accuracy of 7% or less.

12. The multilayer body according to claim 1 ,
wherein at least one surface of the first layer has an arithmetic mean height of 0.001 to 1 μm.

13. The multilayer body according to claim 1 ,
wherein at least one surface of the first layer has a maximum height of 0.1 to 10 μm.

14. The multilayer body according to claim 1 ,
wherein at least one surface of the first layer has an arithmetic mean roughness of 0.005 to 1 μm.

15. The multilayer body according to claim 1 ,
wherein at least one surface of the first layer has a maximum height roughness of 0.05 to 5 μm.

16. The multilayer body according to claim 1 ,
wherein the first layer has a relative crystallinity of 50% or more.

17. The multilayer body according to claim 1 ,
wherein the first layer is a film.

18. A composite material obtained by molding the multilayer body according to claim 1 .

19. The composite material according to claim 18 ,
wherein the composite material is a prepreg.

20. A mobile body comprising the composite material according to claim 18 ,
wherein the mobile body is an airplane, an automobile, a ship or a railroad vehicle.

21. A multilayer body comprising
a first layer comprising a resin containing polyaryletherketone as a main component, and a second layer comprising reinforcing fibers having a number average fiber length of 5 mm or more,
wherein the resin has a molecular weight distribution of 2 or more and less than 4 and a mass average molecular weight of 63000 or more, and
wherein the first layer is a plate-shaped member.

22. The multilayer body according to claim 21 ,
wherein the polyaryletherketone comprises polyetheretherketone.

23. The multilayer body according to claim 21 ,
wherein the plate-shaped member is a film.

24. A method for manufacturing the multilayer body according to claim 1 , the method comprising:
preparing the resin having a molecular weight distribution of 2 or more and less than 4 and a mass average molecular weight of 63000 or more,

melt kneading the resin using an extruder; and
extruding the melted resin from a mouthpiece and cooling the melted resin using a casting roller to form the melted resin into a film,
wherein the film has a number of times of folding endurance of 5000 or more when measured under conditions of: a thickness of 100 μm, a folding angle of 135°, a folding speed of 175 cpm, and a load of 9.8 N, and
wherein a puncture impact strength of the film at 23° C. is 0.3 J or more and the puncture impact strength of the film at −20° C. is 0.3 J or more, and the puncture impact strengths being measured under conditions of: a thickness of 100 μm, a fixing frame inner diameter of 50 mm, a punching striker diameter of 12.7 mm, and a test speed of 3 m/second.

25. The method for manufacturing a multilayer body according to claim 24 ,
wherein the polyaryletherketone has the molecular weight distribution of 2 or more and less than 4 and the mass average molecular weight of 63000 or more.

Assignees

• Mitsubishi Chem Corp

Inventors

• Hasuike Masayasu
• WAKITA Hikari

Classifications

• C08J2361/02

  Condensation polymers of aldehydes or ketones only · CPC title

• C08J5/24

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title

• B29K2071/00

  Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material · CPC title

• B29C48/08 Primary

  flexible, e.g. films · CPC title

• B29C48/022

  characterised by the choice of material · CPC title