Fiber-reinforced thermoplastic resin composition, reinforcing fiber bundle, and process for production of fiber-reinforced thermoplastic resin composition

Patent metadata

Field	Value
Publication number	US-9475929-B2
Application number	US-201113575749-A
Country	US
Kind code	B2
Filing date	Jan 26, 2011
Priority date	Jan 29, 2010
Publication date	Oct 25, 2016
Grant date	Oct 25, 2016

Abstract

The present invention relates to fiber-reinforced thermoplastic resin composition comprising 0.1 to 10 mass % of a (meth)acrylic-based polymer, 1 to 70 mass % of reinforcing fiber, and 20 to 98.9 mass % of thermoplastic resin, wherein the (meth)acrylic-based polymer has, in a side chain, at least one functional group selected from a hydroxyl group, a carboxyl group, an amide group, and an urea group, and has a cohesive energy density (CED) of 385 to 550 MPa. The present invention provides, particularly in the case of using a polyolefin-based resin as matrix resin, a fiber-reinforced thermoplastic resin composition and a reinforcing fiber bundle which have high adhesiveness and good mechanical characteristics.

First claim

The invention claimed is:

1. A fiber-reinforced thermoplastic resin composition comprising:
0.1 to 10 mass % of a (meth)acrylic-based polymer,
1 to 70 mass % of carbon fiber as reinforcing fiber, and
20 to 98.9 mass % of polypropylene as a thermoplastic resin,
wherein the (meth)acrylic-based polymer has, in a side chain, at least one functional group selected from a hydroxyl group, a carboxyl group, an amide group, and an urea group, and has a cohesive energy density (CED) of 385 to 550 MPa as calculated by the following equation:
CED=1.15×Σ{ P ( n )×CE( n )}/Σ{ P ( n )× M ( n )}

wherein assuming that the (meth)acrylic-based polymer contains m types of (meth)acrylic-based monomer units and that each of the (meth)acrylic-based monomer units is referred to as (meth)acrylic-based monomer unit (n) with n being an integer of from one to m, CE(n) denotes the cohesive energy calculated from chemical structure CS(n) of (meth)acrylic-based monomer unit (n), M(n) denotes the molecular weight of (meth)acrylic-based monomer unit (n), and P(n) denotes the molar fraction of (meth)acrylic-based monomer unit (n) in the (meth)acrylic-based polymer, then
Σ P ( n )=1,

wherein the (meth)acrylic-based polymer contains 0 to 5 mass % of a (meth)acrylic-based monomer unit having a carboxyl group, 3 to 25 mass % of a (meth)acrylic-based monomer unit having a hydroxyl group, and 70 to 97 mass % of (meth)acrylic acid alkyl ester unit having an alkyl group with 1 to 4 carbon atoms.

2. The fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the (meth)acrylic-based polymer contains one or more (meth)acrylic-based monomer units selected from a 2-hydroxyethyl methacrylate unit, N-(2-hydroxyethyl) acrylic amide unit, and N-(2-methacryloyl oxyethyl) ethylene urea unit.

3. A fiber-reinforced thermoplastic resin composition comprising:
0.1 to 10 mass % of a (meth)acrylic-based polymer,
1 to 70 mass % of carbon fiber as reinforcing fiber, and
20 to 98.9 mass % of polypropylene as a thermoplastic resin,
wherein the (meth)acrylic-based polymer has, in a side chain, at least one functional group selected from a hydroxyl group, a carboxyl group, an amide group, and an urea group, and has a cohesive energy density (CED) of 385 to 550 MPa as calculated by the following equation:
CED=1.15×Σ{ P ( n )×CE( n )}/Σ{ P ( n )× M ( n )}

wherein assuming that the (meth)acrylic-based polymer contains m types of (meth)acrylic-based monomer units and that each of the (meth)acrylic-based monomer units is referred to as (meth)acrylic-based monomer unit (n) with n being an integer of from one to m, CE(n) denotes the cohesive energy calculated from chemical structure CS(n) of (meth)acrylic-based monomer unit (n), M(n) denotes the molecular weight of (meth)acrylic-based monomer unit (n), and P(n) denotes the molar fraction of (meth)acrylic-based monomer unit (n) in the (meth)acrylic-based polymer, then ΣP(n)=1,
wherein of all the (meth)acrylic-based monomer units in the (meth)acrylic-based polymer, and the (meth)acrylic-based monomer units in which an acryloyloxy group or a methacryloyloxy group is bonded to a hydrogen and/or a primary carbon atom, account for 60 mass % or more.

4. The fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the (meth)acrylic-based polymer has a hydroxyl group in a side chain, and has a hydroxyl value of 10 to 100 mgKOH/g.

5. The fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the (meth)acrylic-based polymer has a carboxyl group in a side chain, and has an acid value of 1 to 10 mgKOH/g.

6. The fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the thermoplastic resin is a modified polyolefin resin containing at least one functional group selected from a carboxyl group, acid anhydride group, and epoxy group.

7. A reinforcing fiber bundle to which a (meth)acrylic-based polymer is attached comprising a (meth)acrylic-based polymer attached to reinforcing carbon fibers, wherein the (meth)acrylic-based polymer contains hydroxyl groups, has a cohesive energy density (CED) of 385 to 550 MPa as calculated by the equation given below, and accounts for 0.1 to 30 mass %;
CED=1.15×Σ{ P ( n )×CE( n )}/Σ{ P ( n )× M ( n )}

wherein assuming that the (meth)acrylic-based polymer contains m types of (meth)acrylic-based monomer units and that each of the (meth)acrylic-based monomer units is referred to as (meth)acrylic-based monomer unit (n) with n being an integer of from one to m, CE(n) denotes the cohesive energy calculated from chemical structure CS(n) of (meth)acrylic-based monomer unit (n), M(n) denotes the molecular weight of (meth)acrylic-based monomer unit (n), and P(n) denotes the molar fraction of (meth)acrylic-based monomer unit (n) in the (meth)acrylic-based polymer, then
Σ P ( n )=1.

8. The reinforcing fiber bundle to which a (meth)acrylic-based polymer is attached according to claim 7 , wherein the (meth)acrylic-based polymer contains 0 to 5 mass % of a (meth)acrylic-based monomer unit having a carboxyl group, 3 to 25 mass % of a (meth)acrylic-based monomer unit having a hydroxyl group, and 70 to 97 mass % of (meth)acrylic acid alkyl ester unit having an alkyl group with 1 to 4 carbon atoms.

Assignees

• Tsuchiya Atsuki
• Sasaki Hideaki
• Honma Masato
• Ando Yumi
• Toray Industries

Inventors

• Tsuchiya Atsuki
• Sasaki Hideaki
• Honma Masato
• Kageishi Ichiji
• Ando Yumi

Classifications

• C08J5/042 Primary

  with carbon fibres · CPC title

• C08L51/06

  grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond · CPC title

• C08L77/00

  Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain (of polyhydrazides C08L79/06; of polyamideimides or polyamide acids C08L79/08); Compositions of derivatives of such polymers · CPC title

• C08L81/04

  Polysulfides · CPC title

• C08J2333/10

  Homopolymers or copolymers of methacrylic acid esters · CPC title