Laminate and method for its production

Patent metadata

Field	Value
Publication number	US-2020338872-A1
Application number	US-202016924299-A
Country	US
Kind code	A1
Filing date	Jul 9, 2020
Priority date	Apr 16, 2018
Publication date	Oct 29, 2020
Grant date	—

Abstract

The purpose of the present invention is to provide a laminate being excellent in chemical resistance, wear resistance, vibration absorption properties and flame resistance, and having high mechanical strength; and a method for its production. A laminate 1 comprises a fiber-reinforced resin layer 20 which comprises a reinforcing fiber base material and a resin component containing at least 50 vol % of a specific fluororesin, wherein the ratio of the reinforcing fiber base material to the total volume of the reinforcing fiber base material and the resin component is from 0.30 to 0.70, and a specific substrate 10, wherein at least one outermost layer is the fiber-reinforced resin layer 20, and the ratio of the total thickness of the fiber-reinforced resin layer 20 to the total thickness of the substrate 10 is from 1/99 to 30/70.

First claim

What is claimed is:

1 . A laminate comprising
a fiber-reinforced resin layer which comprises a reinforcing fiber base material and a resin component containing at least 50 vol % of the following fluororesin, wherein the ratio of the volume of the reinforcing fiber base material to the total volume of the reinforcing fiber base material and the resin component is from 0.30 to 0.70, and a substrate which comprises metal, paper, glass, or a resin component containing more than 50 vol % of the following non-fluororesin, wherein at least one outermost layer is the fiber-reinforced resin layer, and the ratio of the total thickness of the fiber-reinforced resin layer to the total thickness of the substrate is from 1/99 to 30/70, Fluororesin: a melt-moldable fluororesin having at least one type of functional group selected from the group consisting of a carbonyl group-containing group, a hydroxy group, an epoxy group, an amide group, an amino group and an isocyanate group, and having a melting point of from 100 to 325° C., Non-fluororesin: a cured product of a thermosetting resin or a thermoplastic resin, containing no fluorine atom.

2 . The laminate according to claim 1 , wherein the melting point of the fluororesin is at least 150° C. and lower than 260° C.

3 . The laminate according to claim 1 , wherein the melting point of the fluororesin is at least 260° C. and lower than 325° C.

4 . The laminate according to claim 1 , wherein the fluororesin is the following fluorinated polymer,
Fluorinated polymer: a fluorinated polymer having units based on tetrafluoroethylene or chlorotrifluoroethylene, units based on a cyclic hydrocarbon monomer having an acid anhydride group, and units based on a fluorinated monomer (but excluding tetrafluoroethylene and chlorotrifluoroethylene).

5 . The laminate according to claim 1 , wherein reinforcing fibers of the reinforcing fiber base material contained in the fiber-reinforced resin layer are selected from the group consisting of carbon fibers, glass fibers and aramid fibers.

6 . The laminate according to claim 1 , wherein the substrate further contains reinforcing fibers.

7 . The laminate according to claim 1 , wherein the substrate is a resin substrate composed solely of a thermoplastic resin containing no fluorine atom, a fiber-reinforced resin substrate comprising reinforcing fibers and a resin component containing more than 50 vol % of a cured product of a thermosetting resin containing no fluorine atom, or a fiber-reinforced resin substrate comprising reinforcing fibers and a resin component containing more than 50 vol % of a thermoplastic resin containing no fluorine atom.

8 . The laminate according to claim 1 , wherein the thermoplastic resin containing no fluorine atom is selected from the group consisting of a polyamide, a polyarylene sulfide resin, a polyketone, a polyetherketone, a polyetheretherketone, a polyetherketoneketone, a polyethernitrile, a modified polyphenylene ether, a thermoplastic polyimide, a polyamideimide, a polyetherimide, a polysulfone, a polyethersulfone and a polyarylate.

9 . The laminate according to claim 1 , wherein the thermosetting resin containing no fluorine atom is selected from the group consisting of an epoxy resin, a cyanate ester resin, an unsaturated polyester resin, a vinyl ester resin, a phenol resin, a urea melamine resin, a polyimide and a bismaleimide resin.

10 . The laminate according to claim 6 , wherein the reinforcing fibers contained in the substrate are selected from the group consisting of carbon fibers, glass fibers and aramid fibers.

11 . The laminate according to claim 1 , wherein the structure of the substrate is a columnar shape, a cylindrical shape or a honeycomb structure.

12 . The laminate according to claim 1 , wherein the adhesive strength between the fiber-reinforced resin layer and the substrate is at least 5 N/cm.

13 . A method for producing a laminate, which comprises laminating
a prepreg having a reinforcing fiber base material impregnated with a resin component containing at least 50 vol % of the following fluororesin, wherein the ratio of the volume of the reinforcing fiber base material to the total volume of the reinforcing fiber base material and the resin component is from 0.30 to 0.70, and a substrate comprising metal, paper, glass or a resin component containing more than 50 vol % of the following non-fluororesin, so that the prepreg is disposed on at least one outermost layer, and the ratio of the total thickness of the prepreg to the total thickness of the substrate becomes to be from 1/99 to 30/70, and heating and pressing them, Fluororesin: a melt-moldable fluororesin having at least one type of functional group selected from the group consisting of a carbonyl group-containing group, a hydroxy group, an epoxy group, an amide group, an amino group and an isocyanate group, and having a melting point of from 100 to 325° C., Non-fluororesin: an uncured thermosetting resin or thermoplastic resin containing no fluorine atom.

14 . The method for producing a laminate according to claim 13 , wherein the surface of the prepreg in contact with the substrate is plasma-treated.

15 . A vibration-damping member made of the laminate as defined in claim 1 .

Assignees

• Agc Inc

Inventors

• Ozawa Norio
• Hosoda Tomoya
• Sato Takashi

Classifications

• C08J5/243

  using carbon fibres · CPC title

• B32B27/38

  comprising epoxy resins · CPC title

• B32B2250/05

  5 or more layers · CPC title

• B32B15/043

  of metal (B32B15/01 takes precedence) · CPC title

• B32B27/10

  of paper or cardboard · CPC title