Carbon fiber-reinforced thermoplastic resin composition, and pellets and molded article thereof

Patent metadata

Field	Value
Publication number	US-9803061-B2
Application number	US-201214355913-A
Country	US
Kind code	B2
Filing date	Nov 19, 2012
Priority date	Nov 29, 2011
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

A carbon fiber-reinforced thermoplastic resin composition includes a thermoplastic resin (A), a carbon fiber (B), and a titanium compound (C), an amount of the thermoplastic resin (A) being 10 to 65% by weight, an amount of the carbon fiber (B) being 35 to 90% by weight, based on 100% by weight of the total amount of the thermoplastic resin (A) and the carbon fiber (B), and an amount of the titanium compound (C) being 0.01 to 5 parts by weight, based on 100 parts by weight of the total amount of the thermoplastic resin (A) and the carbon fiber (B).

First claim

The invention claimed is:

1. A carbon fiber-reinforced thermoplastic resin composition, comprising:
a thermoplastic resin (A);
a carbon fiber (B); and
a titanium compound (C),
an amount of the thermoplastic resin (A) being 10 to 65% by weight, an amount of the carbon fiber (B) being 35 to 90% by weight, based on 100% by weight of the total amount of the thermoplastic resin (A) and the carbon fiber (B), and an amount of the titanium compound (C) being 1) 0.01 to 5 parts by weight, based on 100 parts by weight of the total amount of the thermoplastic resin (A) and the carbon fiber (B), and 2) 0.1 to 1.5% by weight of the amount of the carbon fiber (B).

2. The carbon fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the titanium compound (C) is titanium oxide.

3. The carbon fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the thermoplastic resin (A) is at least one selected from the group consisting of a polyamide resin, a polycarbonate resin, and a polyester resin.

4. The carbon fiber-reinforced thermoplastic resin composition according to claim 3 , wherein the thermoplastic resin (A) is a polyamide resin.

5. The carbon fiber-reinforced thermoplastic resin composition according to claim 4 , wherein the polyamide resin has a melting point (Tm) of 250 to 350° C., as determined by thermal analysis using a differential scanning calorimeter (DSC).

6. The carbon fiber-reinforced thermoplastic resin composition according to claim 4 , wherein the polyamide resin has a difference between a melting point (Tm) and a crystallization temperature at descending temperature (Tc) of 0° C. to 50° C., wherein Tm and Tc are determined by thermal analysis using a differential scanning calorimeter (DSC).

7. The carbon fiber-reinforced thermoplastic resin composition according to claim 4 , wherein the polyamide resin is at least one selected from the group consisting of polyamide 6, polyamide 66, polyamide MXD6, polyamide 9T, polyamide 10T, and copolyamides thereof.

8. The carbon fiber-reinforced thermoplastic resin composition according to claim 4 , wherein the polyamide resin comprises an aromatic group-containing crystalline polyamide resin (a) and an amorphous polyamide resin (b), the amount of the aromatic group-containing crystalline polyamide resin (a) being 1 to 99% by weight, the amount of the amorphous polyamide resin (b) being 99 to 1% by weight, based on 100% by weight of the total amount of (a) and (b).

9. The carbon fiber-reinforced thermoplastic resin composition according to claim 8 , wherein the aromatic group-containing crystalline polyamide resin (a) has a melting point (Tm) of 250 to 350° C., as determined by thermal analysis using a differential scanning calorimeter (DSC).

10. The carbon fiber-reinforced thermoplastic resin composition according to claim 8 , wherein the aromatic group-containing crystalline polyamide resin (a) has a difference between a melting point (Tm) and a crystallization temperature at descending temperature (To) of 0° C. to 50° C., wherein Tm and Tc are determined by thermal analysis using a differential scanning calorimeter (DSC).

11. The carbon fiber-reinforced thermoplastic resin composition according to claim 8 , wherein the aromatic group-containing crystalline polyamide resin (a) is at least one selected from the group consisting of polyamide 9T, polyamide 10T, polyamide 6T/66, polyamide 12T, 10T/1012, and polyamide 6T.

12. The carbon fiber-reinforced thermoplastic resin composition according to claim 1 , further comprising 0.1 to 20 parts by weight of a granular filler (D), based on 100 parts by weight of the total of the thermoplastic resin (A) and the carbon fiber (B).

13. A pellet produced by molding the carbon fiber-reinforced thermoplastic resin composition according to claim 1 , wherein the carbon fiber in the pellet has a weight average fiber length of 0.01 to 2 mm.

14. A molded article produced by molding the pellet according to claim 13 .

15. The molded article according to claim 14 , wherein the carbon fiber in the molded article has a weight average fiber length of 0.01 to 0.5 mm.

16. The molded article according to claim 14 , having a flexural modulus of 20 GPa or more, and an arithmetic mean height (Wa) value of an undulating curve of 3.0 μm or less.

Assignees

• Toray Industries

Inventors

• Hattori Kimihiko
• Tamai Akiyoshi
• Utazaki Kenichi

Classifications

• C08J2377/00

  Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers · CPC title

• C08K2003/2241

  Titanium dioxide · CPC title

• C08J5/042

  with carbon fibres · CPC title

• B29B7/90 Primary

  Fillers or reinforcements {, e.g. fibres} · CPC title

• B29B9/14

  fibre-reinforced · CPC title