Molded article and molding material

Patent metadata

Field	Value
Publication number	US-9902840-B2
Application number	US-201415030641-A
Country	US
Kind code	B2
Filing date	Oct 24, 2014
Priority date	Oct 29, 2013
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

A molded article includes 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article, wherein (I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa, (II) number average fiber length of the reinforcing fibers (A) is 0.4 to 10 mm, (III) tensile elongation of the matrix resin (B) is 1.5 to 10%, and (IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.

First claim

The invention claimed is:

1. A molded article comprising: 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B), wherein the matrix resin (B) is a carbodiimide-modified polyarylene sulfide obtained from a polyarylene sulfide and a carbodiimide compound, and the content of the carbodiimide compound is 0.1 to 10% by mass based on 100% by mass of the matrix resin (B), the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article:
(I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa;
(II) number average fiber length of the reinforcing fibers (A) in the molded article is 0.4 to 10 mm;
(III) tensile elongation of the matrix resin (B) is 1.5 to 10%; and
(IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.

2. The molded article according to claim 1 , wherein the tensile strength in the main orientation direction of the reinforcing fibers in the molded article is 280 MPa or more.

3. The molded article according to claim 1 , wherein the tensile strength in the main orientation direction of the reinforcing fibers in the molded article is 300 MPa or more.

4. The molded article according to claim 1 , wherein the tensile strength in a direction orthogonal to the main orientation direction of the reinforcing fibers in the molded article is 150 MPa or more.

5. The molded article according to claim 1 , wherein an average of lengths of the reinforcing fibers (A) observed from a breakage cross-section after tension breakage of the molded article is 0.2 mm or less.

6. The molded article according to claim 1 , wherein the matrix resin (B) is deposited on the surfaces of the reinforcing fibers (A) observed from the cross-section after tension breakage of the molded article.

7. The molded article according to claim 1 , wherein the tensile elongation of the matrix resin (B) is 2.5 to 10%.

8. The molded article according to claim 1 , wherein a ratio of the number of fibers dispersed in the form of monofilaments to the number of reinforcing fiber (A) (fiber dispersion ratio P) in the molded article is 90 to 100%.

9. The molded article according to claim 1 , comprising 20 to 40% by mass of the reinforcing fibers (A) and 60 to 80% by mass of the matrix resin (B).

10. The molded article according to claim 1 , wherein the reinforcing fibers (A) are carbon fibers having a strand tensile strength of 4 to 5 GPa.

11. The molded article according to claim 1 , wherein the reinforcing fibers (A) are carbon fibers surface-treated with a compound having, in one molecule, three or more functional groups of at least one type selected from the group consisting of a carboxyl group, an amino group, a hydroxyl group and an epoxy group.

12. The molded article according to claim 1 , wherein mass average molecular weight of the polyarylene sulfide as a main component of the matrix resin (B) is 10,000 to 40,000.

13. The molded article according to claim 1 , wherein the molded article is produced by injection molding.

14. A molding material for producing the molded article according to claim 1 .

15. The molding material according to claim 14 , wherein the number average fiber length of the reinforcing fibers (A) is 4 to 10 mm.

16. A molded article comprising: 10 to 40% by mass of reinforcing fibers (A); and 60 to 90% by mass of a matrix resin (B) mainly including a polyarylene sulfide, the molded article satisfying conditions (I) to (IV) and having a tensile strength of 240 MPa or more in a main orientation direction of the reinforcing fibers (A) in the molded article:
(I) strand tensile strength of the reinforcing fibers (A) is 1.5 to 5.5 GPa;
(II) number average fiber length of the reinforcing fibers (A) in the molded article is 0.6 to 10 mm;
(III) tensile elongation of the matrix resin (B) is 1.5 to 10%; and
(IV) interfacial shear strength between the reinforcing fibers (A) and the matrix resin (B) is 20 MPa or more.

Assignees

• Toray Industries

Inventors

• Imai Naokichi
• Sano Kentaro
• Inose Keisuke

Classifications

• B29K2281/04

  Polysulfides, e.g. PPS, i.e. polyphenylene sulfide, or derivatives thereof · CPC title

• B29C45/0001

  characterised by the choice of material · CPC title

• B29C70/14 Primary

  oriented · CPC title

• C08K2201/004

  Additives being defined by their length · CPC title

• C08L81/00

  Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers · CPC title