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US-12617910-B2 - Member for composite material, composite material, mobile body, and method for manufacturing film for composite material

US12617910B2US 12617910 B2US12617910 B2US 12617910B2US-12617910-B2

Abstract

The following is provided as a member for a composite material that has excellent stiffness, heat resistance, and productivity. A member for a composite material containing resin component that contains polyaryletherketone as a main component. The resin component has a molecular weight distribution of 3.8 or more and 8 or less and a mass average molecular weight of 86000 or less. The member for a composite material has a thickness more than 15 μm. The composite material contains a resin and reinforcing fibers having a number average fiber length of 5 mm or more.

Inventors

  • Masayasu HASUIKE
  • Hikari Wakita

Assignees

  • MITSUBISHI CHEMICAL CORPORATION

Dates

Publication Date
20260505
Application Date
20220624
Priority Date
20191227

Claims (20)

  1. 1 . A multilayer body, comprising a first layer comprising a resin containing polyaryletherketone as a main component, and a second layer comprising reinforcing fibers having a number average fiber length of 5 mm or more, wherein the resin has a molecular weight distribution of 3.8 or more and 8 or less and a mass average molecular weight of 86000 or less, wherein the first layer has a thickness more than 15 μm and at least one surface of the first layer has an arithmetic mean roughness of 0.005 to 1 μm.
  2. 2 . The multilayer body according to claim 1 , wherein the polyaryletherketone comprises polyetheretherketone.
  3. 3 . The multilayer body according to claim 1 , wherein a percentage of a content of the polyaryletherketone in the resin is more than 90 mass %.
  4. 4 . The multilayer body according to claim 1 , wherein the polyaryletherketone has the molecular weight distribution of 3.8 or more and 8 or less and the mass average molecular weight of 86000 or less.
  5. 5 . The multilayer body according to claim 1 , wherein the first layer has a crystal heat of fusion of 43 J/g or more and 60 J/g or less.
  6. 6 . The multilayer body according to claim 1 , wherein the first layer has a crystallization temperature of 299° C. or more and 320° C. or less.
  7. 7 . The multilayer body according to claim 1 , wherein a tensile modulus of the first layer measured at a tension rate of 5 mm/minute is 3450 MPa or more and 5000 MPa or less.
  8. 8 . The multilayer body according to claim 1 , wherein the first layer has a thickness accuracy of 7% or less.
  9. 9 . The multilayer body according to claim 1 , wherein at least one surface of the first layer has an arithmetic mean height of 0.001 to 1 μm.
  10. 10 . The multilayer body according to claim 1 , wherein at least one surface of the first layer has a maximum height of 0.1 to 10 μm.
  11. 11 . The multilayer body according to claim 1 , wherein at least one surface of the first layer has a maximum height roughness of 0.05 to 5 μm.
  12. 12 . The multilayer body according to claim 1 , wherein the first layer has a relative crystallinity of 50% or more.
  13. 13 . The multilayer body according to claim 1 , wherein the first layer is a film.
  14. 14 . A composite material obtained by molding the multilayer body according to claim 1 .
  15. 15 . The composite material according to claim 14 , wherein the composite material is a prepreg.
  16. 16 . A mobile body comprising the composite material according to claim 14 , wherein the mobile body is an airplane, an automobile, a ship, or a railroad vehicle.
  17. 17 . A method for manufacturing the multilayer body according to claim 1 , the method comprising: preparing the resin having a molecular weight distribution of 3.8 or more and 8 or less and a mass average molecular weight of 86000 or less; melt kneading the resin using an extruder; extruding the melted resin from a mouthpiece; and cooling the melted resin using a casting roller to form the melted resin into a film, wherein a crystallization temperature of the film is 299° C. or more and 320° C. or less, and a tensile modulus of the cooled film measured at a tension rate of 5 mm/minute is 3450 MPa or more and 5000 MPa or less.
  18. 18 . The method for manufacturing a multilayer body according to claim 17 , wherein the polyaryletherketone has the molecular weight distribution of 3.8 or more and 8 or less and the mass average molecular weight of 86000 or less.
  19. 19 . A multilayer body comprising a first layer comprising a resin comprising polyaryletherketone as a main component, and a second layer comprising reinforcing fibers having a number average fiber length of 5 mm or more, wherein the resin has a molecular weight distribution of 3.8 or more and 8 or less and a mass average molecular weight of 86000 or less, wherein at least one surface of the first layer has an arithmetic mean roughness of 0.005 to 1 μm, wherein the first layer is a plate-shaped member, and wherein the plate-shaped member has a thickness more than 15 μm.
  20. 20 . The multilayer body according to claim 19 , wherein the polyaryletherketone comprises polyetheretherketone.

Description

RELATED APPLICATIONS This application is a continuation of International Application No. PCT/JP2020/048322, filed on Dec. 24, 2020, which claims priority to Japanese Patent Application No. 2019-237639, filed on Dec. 27, 2019, and Japanese Patent Application Nos. 2020-096903 and 2020-096904, filed on Jun. 3, 2020, the entire contents of each of which being herein incorporated by reference. TECHNICAL FIELD The present disclosure relates to a member for a composite material that is constituted by polyaryletherketone and is applicable to composite materials used in electrical or electronic devices, automobiles, airplanes, and the like, and also relates to a composite material and a mobile body in which the member for a composite material is used. The present disclosure also relates to a method for manufacturing a film for a composite material. BACKGROUND ART In recent years, super engineering plastics represented by polyetheretherketone (PEEK), polyetherimide sulfone (PEI), polyethersulfone (PES), polyether ketone (PEK), polyether ketone ketone (PEKK), polyether ketone ether ketone ketone (PEKEKK), and the like have been widely adopted for films used in electrical or electronic devices, automobiles, airplanes, and the like because the super engineering plastics have high heat resistance, mechanical properties, chemical resistance, and durability. In particular, polyetheretherketone has excellent heat resistance, mechanical properties, chemical resistance, and the like, and therefore is used as a matrix material for fiber-reinforced materials. In order to sufficiently exhibit these properties, resin needs to be crystallized, but crystallization of polyetheretherketone progresses slowly in some cases, and there are demands for a material with which a crystallized article can be produced with high productivity. PTL 1 discloses a composite material that contains polyetheretherketone as a matrix and fibers sized with polyethersulfone as a reinforcing material. PTL 2 discloses a fiber-reinforced thermoplastic resin prepreg in which a polyaryl ketone resin composition having a specific intrinsic viscosity is used. RELATED ART DOCUMENTS Patent Documents PTL 1: JP-A-SH062(1987)-115033PTL 2: JP-A-2019-147876 SUMMARY However, the inventors found through examination that the polyetheretherketone described in PTL 1 has a narrow molecular weight distribution and the polyaryl ketone described in PTL 2 has a large molecular weight, and therefore, a problem may arise in productivity when a member for a composite material is produced, or the stiffness and heat resistance of the obtained member for a composite material may be insufficient in applications in which higher performance is required. The present disclosure was made under the above circumstances, and provides a member for a composite material and the like that has excellent stiffness and heat resistance, and also has excellent productivity. As a means for solving the problems of conventional art described above, the present disclosure provides a member for a composite material and the like in which polyaryletherketone having a specific molecular weight distribution and a specific molecular weight is used. That is, the present disclosure provides the following [1] to [22]. [1] A member for a composite material containing a resin component that contains polyaryletherketone as a main component, wherein the resin component has a molecular weight distribution of 3.8 or more and 8 or less and a mass average molecular weight of 86000 or less, wherein the member for a composite material has a thickness more than 15 μm, and wherein the composite material contains a resin and reinforcing fibers having a number average fiber length of 5 mm or more. [2] The member for a composite material according to [1], wherein the polyaryletherketone is polyetheretherketone. [3] The member for a composite material according to [1] or [2], wherein a percentage of the content of polyaryletherketone in the resin component is more than 90 mass %. [4] The member for a composite material according to any one of [1] to [3], wherein the polyaryletherketone has the molecular weight distribution of 3.8 or more and 8 or less and the mass average molecular weight of 86000 or less. [5] The member for a composite material according to any one of [1] to [4], wherein the member has a crystal heat of fusion of 43 J/g or more and 60 J/g or less. [6] The member for a composite material according to any one of [1] to [5], wherein the member has a crystallization temperature of 299° C. or more and 320° C. or less. [7] The member for a composite material according to any one of [1] to [6], wherein a tensile modulus of the member measured at a tension rate of 5 mm/minute is 3450 MPa or more and 5000 MPa or less. [8] The member for a composite material according to any one of [1] to [7], wherein the member has a thickness accuracy of 7% or less. [9] The member for a composite material according to any one of [1] to [8