Production method for fibre-reinforced composite material, prepreg, particle-containing resin composition, and fibre-reinforced composite material

Patent metadata

Field	Value
Publication number	US-2016297942-A1
Application number	US-201415037557-A
Country	US
Kind code	A1
Filing date	Oct 28, 2014
Priority date	Nov 19, 2013
Publication date	Oct 13, 2016
Grant date	—

Abstract

A production method for a fiber-reinforced composite material comprises: a step of stacking a prepreg plurally to obtain a prepreg-stacked body; and a step of heating the prepreg-stacked body to cure a resin, wherein the prepreg comprises: a reinforcing fiber layer including reinforcing fibers and a resin composition with which the space between fibers of the reinforcing fibers is impregnated and which contains (A) a benzoxazine resin, (B) an epoxy resin, and (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule; and a surface layer provided on at least one surface of the reinforcing fiber layer and containing (A) to (C) components, and (D) polyamide resin particles having an average particle size of 5 to 50 μm.

First claim

1 . A production method for a fiber-reinforced composite material comprising:
a step of stacking a prepreg plurally to obtain a prepreg-stacked body; and a step of heating the prepreg-stacked body to cure a resin, wherein the prepreg comprises: a reinforcing fiber layer including reinforcing fibers and a resin composition with which a space between fibers of the reinforcing fibers is impregnated and which contains (A) a benzoxazine resin, (B) an epoxy resin, and (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule; and a surface layer provided on at least one surface of the reinforcing fiber layer and containing (A) a benzoxazine resin, (B) an epoxy resin, (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule, and (D) polyamide resin particles having an average particle size of 5 to 50 μm, wherein the polyamide resin particles include (D1) a first polyamide resin particle and (D2) a second polyamide resin particle having a higher melting temperature measured in a composition constituting the surface layer than the first polyamide resin particle has.

2 . The production method for a fiber-reinforced composite material according to claim 1 ,
wherein a melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is 120 to 170° C.; and a melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is 175 to 220° C.

3 . The production method for a fiber-reinforced composite material according to claim 1 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

4 . The production method for a fiber-reinforced composite material according to claim 1 , wherein the surface layer contains 65 to 78 parts by mass of the (A) component, 22 to 35 parts by mass of the (B) component, 5 to 20 parts by mass of the (C) component, and 15 to 45 parts by mass of the (D) component when it is assumed that a total amount of the (A) component and the (B) component is 100 parts by mass.

5 . A prepreg comprising:
a reinforcing fiber layer including reinforcing fibers and a resin composition with which a space between fibers of the reinforcing fibers is impregnated and which contains (A) a benzoxazine resin, (B) an epoxy resin, and (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule; and a surface layer provided on at least one surface of the reinforcing fiber layer and containing (A) a benzoxazine resin, (B) an epoxy resin, (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule, and (D) polyamide resin particles having an average particle size of 5 to 50 μm, wherein the polyamide resin particles include (D1) a first polyamide resin particle and (D2) a second polyamide resin particle having a higher melting temperature measured in a composition constituting the surface layer than the first polyamide resin particle has.

6 . The prepreg according to claim 5 ,
wherein a melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is 120 to 170° C.; and a melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is 175 to 220° C.

7 . The prepreg according to claim 5 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

8 . The prepreg according to claim 5 , wherein the surface layer contains 65 to 78 parts by mass of the (A) component, 22 to 35 parts by mass of the (B) component, 5 to 20 parts by mass of the (C) component, and 15 to 45 parts by mass of the (D) component when it is assumed that a total amount of the (A) component and the (B) component is 100 parts by mass.

9 . A resin composition containing particles, comprising:
(A) a benzoxazine resin; (B) an epoxy resin; (C) a curing agent having 2 or more phenolic hydroxy groups in a molecule; and (D) polyamide resin particles having an average particle size of 5 to 50 μm, wherein the polyamide resin particles include (D1) a first polyamide resin particle and (D2) a second polyamide resin particle having a higher melting temperature measured in the composition than the first polyamide resin particle has.

10 . The resin composition containing particles according to claim 9 ,
wherein a melting temperature of the (D1) first polyamide resin particles measured in the resin composition containing particles is 120 to 170° C.; and a melting temperature of the (D2) second polyamide resin particles measured in the resin composition containing particles is 175 to 220° C.

11 . The resin composition containing particles according to claim 9 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the resin composition containing particles is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the resin composition containing particles is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

12 . The resin composition containing particles according to claim 9 , wherein the surface layer contains 65 to 78 parts by mass of the (A) component, 22 to 35 parts by mass of the (B) component, 5 to 20 parts by mass of the (C) component, and 15 to 45 parts by mass of the (D) component when it is assumed that a total amount of the (A) component and the (B) component is 100 parts by mass.

13 . A fiber-reinforced composite material obtained by stacking the prepreg according to claim 5 plurally and performing heating under increased pressure.

14 . The production method for a fiber-reinforced composite material according to claim 2 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

15 . The prepreg according to claim 6 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the composition constituting the surface layer is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the composition constituting the surface layer is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

16 . The resin composition containing particles according to claim 10 ,
wherein, when it is assumed that the melting temperature of the (D1) first polyamide resin particles measured in the resin composition containing particles is M 1 ° C. and the melting temperature of the (D2) second polyamide resin particles measured in the resin composition containing particles is M 2 ° C., a value of (M 2 −M 1 ) is 5 or more.

17 . A fiber-reinforced composite material obtained by stacking the prepreg according to claim 6 plurally and performing heating

Assignees

• Jx Nippon Oil & Energy Corp
• Fuji Heavy Ind Ltd

Inventors

• Minami Masaki
• Matsumoto Takayuki
• Fukuda Yoshihiro
• Sekine Naoyuki
• Nakajima Masanori

Classifications

• B32B2307/306

  Resistant to heat · CPC title

• C08J2379/06

  Polyhydrazides; Polytriazoles; Polyamino-triazoles; Polyoxadiazoles · CPC title

• B32B2307/7265

  Non-permeable · CPC title

• C08J2463/00

  Characterised by the use of epoxy resins; Derivatives of epoxy resins · CPC title

• B29K2105/0872

  Prepregs · CPC title