Resin precursor composition for impregnating fiber assemblies

Abstract

The present invention provides a resin precursor composition for impregnating a fiber assembly, which has excellent impregnation ability into the fiber assembly. [Solution] A resin precursor composition for impregnating a fiber assembly, comprising 2,5-bis(hydroxymethyl)furan (component A).

Description

[Technical Field]

[0001] The present invention relates to a resin precursor composition for impregnating a fiber assembly. [Background technology]

[0002] Furan resins are used as matrix resins in laminates that use fibrous substrates such as carbon fibers and glass fibers (for example, Patent Documents 1 and 2).

[0003] Patent Document 2 discloses a thermosetting furan resin composition containing a furan resin and / or a modified furan resin, at least one furfural derivative selected from the group consisting of furan-3-carboxylic acid, furan-2,5-dimethanol, 2,5-furandicarboxylic acid, and hydroxymethylfurfural, and an acidic curing agent. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2018-76468 [Patent Document 2] Japanese Patent Application Laid-Open No. 2013-213140 Summary of the Invention [Problem to be solved by the invention]

[0005] Although furan resins have excellent heat resistance and solvent resistance, they have the problem that they are difficult to impregnate into fiber assemblies such as fibrous substrates.

[0006] The present invention provides a resin precursor composition for impregnating a fiber assembly, which has excellent impregnation properties into a fiber assembly. [Means for solving the problem]

[0007] The present invention provides The resin precursor composition for impregnating a fiber assembly contains 2,5-bis(hydroxymethyl)furan (component A). [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a resin precursor composition for impregnating a fiber assembly, which has excellent impregnation ability into a fiber assembly. DETAILED DESCRIPTION OF THE INVENTION

[0009] <Resin precursor composition for impregnating fiber assembly> The resin precursor composition for impregnation of a fiber assembly (hereinafter also simply referred to as the precursor composition) of this embodiment contains 2,5-bis(hydroxymethyl)furan (component A). The precursor composition of this embodiment has excellent impregnation properties into a fiber assembly.

[0010] From the viewpoint of improving the impregnation property into the fiber assembly, the content of the component A in the precursor composition is preferably 10% by mass or more, more preferably 15% by mass or more, even more preferably 18% by mass or more, still more preferably 20% by mass or more, still more preferably 50% by mass or more, and still more preferably 80% by mass or more. The content of the component A in the precursor composition is not particularly limited, but is preferably 100% by mass.

[0011] The precursor composition of this embodiment may contain furfuryl alcohol (component B) from the viewpoint of improving the stability of curing.

[0012] The content of Component B in the precursor composition is preferably 10% by mass or more from the viewpoint of improving curing stability, and is preferably 90% by mass or less, more preferably 80% by mass or less, even more preferably 50% by mass or less, still more preferably 20% by mass or less, and even more preferably 0% by mass from the viewpoint of improving impregnation into a fiber assembly.

[0013] From the viewpoint of improving the impregnation property into a fiber assembly, the mass ratio of the component A to the component B in the precursor composition (the component A / the component B) is preferably 10 / 90 or more, more preferably 20 / 80 or more, even more preferably 50 / 50 or more, still more preferably 80 / 20 or more, and still more preferably 100 / 0. From the viewpoint of improving the curing stability, the mass ratio of the component A to the component B in the precursor composition (the component A / the component B) is 100 / 0 or less, preferably 80 / 20 or less.

[0014] The fibers constituting the fiber assembly are not particularly limited, and known fibers can be appropriately selected depending on the application, etc. Examples of the fibers constituting the fiber assembly include one or more fibers selected from the group consisting of carbon fibers, glass fibers, pulp fibers, aramid fibers, nylon fibers, high-strength polyester fibers, boron fibers, alumina fibers, and silicon nitride fibers.

[0015] The form of the fiber assembly to be impregnated with the precursor composition is not particularly limited and can be appropriately selected depending on the application, etc. Examples of the form of the fiber assembly include one or more types selected from the group consisting of unidirectional (UD) fiber assembly in which the fibers constituting the fiber assembly are aligned in one direction, woven fabric, nonwoven fabric, and non-crimp fabric.

[0016] The precursor composition may contain a filler, a plasticizer, a foam stabilizer, etc., within the range that does not impair the effects of the present invention.

[0017] <Prepreg> The prepreg of the present embodiment contains the fiber assembly and an uncured product and / or semi-cured product of the precursor composition.

[0018] The content of the fiber aggregate in the prepreg is not particularly limited, but can generally be set to 10% by mass or more and 90% by mass or less.

[0019] The total content of the uncured and semi-cured precursor composition in the prepreg is not particularly limited, but can generally be 10% by mass or more and 90% by mass or less.

[0020] <Prepreg manufacturing method> The manufacturing method of this embodiment is a method for manufacturing the prepreg, and includes a step (1) of impregnating the fiber assembly with an impregnation composition that is a mixture of the precursor composition and a curing agent.

[0021] The curing agent can be any curing agent that can cure the precursor composition without any particular limitation. Examples of the curing agent include acid-based curing agents, and one or more of conventionally known curing agents can be used, such as sulfonic acid compounds such as xylenesulfonic acid (particularly m-xylenesulfonic acid), toluenesulfonic acid (particularly p-toluenesulfonic acid), and methanesulfonic acid, phosphoric acid, phosphoric acid compounds such as acidic phosphate esters, and sulfuric acid.

[0022] In the step (1), the mass ratio of the precursor composition to the curing agent in the impregnation composition can be appropriately set. From the viewpoint of increasing the curing rate of the impregnation composition and improving the strength of the composite material obtained by curing the impregnation composition impregnated into the fiber assembly, the mass ratio of the curing agent can generally be set to 0.1 parts by mass or more and 10 parts by mass or less per 100 parts by mass of the precursor composition.

[0023] In the step (1), the method for impregnating the fiber assembly with the impregnation composition is not particularly limited, and any known method can be used for impregnation. Examples of the method for impregnating the fiber assembly with the impregnation composition include a method in which the fiber assembly is impregnated with the impregnation composition using an impregnation roll, and a method in which the fiber assembly is immersed in the impregnation composition.

[0024] When the prepreg has a semi-cured product of the precursor composition, the manufacturing method of this embodiment includes a step (2) of semi-curing an impregnation composition, which is a mixture of the precursor composition and the curing agent impregnated into the fiber assembly.

[0025] In the step (2), the method for semi-curing the impregnation composition impregnated into the fiber assembly is not particularly limited, and the composition can be cured by a known method depending on the curing agent used.

[0026] <Composite materials> The composite material of the present embodiment contains the fiber assembly and a cured product of the precursor composition.

[0027] The content of the fiber aggregate in the composite material is not particularly limited, but can generally be 10% by mass or more and 90% by mass or less.

[0028] The content of the cured product of the precursor composition in the composite material is not particularly limited, but can generally be 10% by mass or more and 90% by mass or less.

[0029] <Method of manufacturing composite materials> The manufacturing method of this embodiment is a method for manufacturing the composite material, and includes a step (1) of impregnating the fiber assembly with an impregnation composition, which is a mixture of the precursor composition and the curing agent, and a step (3) of curing the impregnation composition impregnated into the fiber assembly.

[0030] Step (1) in the method for producing a composite material of this embodiment is the same as step (1) in the method for producing a prepreg, and therefore a description thereof will be omitted.

[0031] In the step (3), the method for curing the impregnation composition is not particularly limited, and the composition can be cured by a known method depending on the curing agent used. [Example]

[0032] <Examples and Comparative Examples> 2,5-bis(hydroxymethyl)furan (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) and furfuryl alcohol (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) were mixed to the contents shown in Table 1 to obtain a resin precursor composition for impregnating a fiber assembly according to each example and comparative example.

[0033] <Evaluation method> [Measurement of the amount of adhesion to the fiber assembly] A glass fiber sheet (15 mm long x 15 mm wide: 0.05 g; GC-70 manufactured by Muto Shoji Co., Ltd.) was immersed for 1 minute in the resin precursor composition for impregnating a fiber assembly according to each example and comparative example, which had been heated to 80°C on a hot plate (HPA1914B manufactured by Kenis Co., Ltd.). The glass fiber sheet was then removed from the resin precursor composition for impregnating a fiber assembly, and the mass of the resin precursor composition for impregnating a fiber assembly adhered to 1 g of the glass fiber sheet was determined. The greater the mass (g / g) of the resin precursor composition for impregnating a fiber assembly adhered to 1 g of the glass fiber sheet, the easier it was to impregnate the fiber assembly. The evaluation results are shown in Table 1.

[0034] [Table 1]

Claims

1. A resin precursor composition for impregnating a fiber assembly, comprising 2,5-bis(hydroxymethyl)furan (component A).

2. The resin precursor composition for impregnating a fiber assembly according to claim 1, wherein the content of said component A is 10% by weight or more.

3. The resin precursor composition for impregnating a fiber assembly according to claim 1 , further comprising furfuryl alcohol (component B).

4. The resin precursor composition for impregnating a fiber assembly according to claim 3, wherein a mass ratio of the component A to the component B (the component A / the component B) is 10 / 90 or more and 100 / 0 or less.

5. 2. The resin precursor composition for impregnating a fiber assembly according to claim 1, wherein the fibers constituting the fiber assembly to be impregnated with the resin precursor composition for impregnating a fiber assembly are at least one type of fibers selected from the group consisting of carbon fibers, glass fibers, and pulp fibers.

6. A prepreg comprising a fiber assembly and an uncured and / or semi-cured resin precursor composition for impregnating a fiber assembly according to any one of claims 1 to 5.

7. 7. The prepreg according to claim 6, wherein the fibers constituting the fiber assembly are at least one type selected from the group consisting of carbon fibers, glass fibers, and pulp fibers.

8. 7. A method for producing a prepreg according to claim 6, comprising: a step (1) of impregnating the fiber assembly with an impregnation composition which is a mixture of the resin precursor composition for impregnating a fiber assembly and a curing agent for curing the resin precursor composition for impregnating a fiber assembly.

9. The method for producing a prepreg according to claim 8, further comprising a step (2) of semi-curing the impregnation composition with which the fiber assembly has been impregnated.

10. A composite material comprising a fiber assembly and a cured product of the resin precursor composition for impregnating a fiber assembly according to any one of claims 1 to 5.

11. 11. The composite material according to claim 10, wherein the fibers constituting the fiber assembly are at least one type selected from the group consisting of carbon fibers, glass fibers, and pulp fibers.

12. 11. A method for producing a composite material according to claim 10, comprising: a step (1) of impregnating the fiber assembly with an impregnation composition, the impregnation composition being a mixture of the resin precursor composition for impregnating a fiber assembly and a curing agent for curing the resin precursor composition for impregnating a fiber assembly; and a step (3) of curing the impregnation composition with which the fiber assembly has been impregnated.

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