JP2012056232A - Method of manufacturing composite reinforced fiber bundle, and molding material using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite reinforced fiber bundle favorable in impregnating ability into a reinforced fiber bundle, reduced in void, and reduced in volatile component when molding, and a molding material using the composite reinforced fiber bundle capable of manufacturing a molded product favorable in fiber dispersion into the molded product.SOLUTION: A method of manufacturing a composite reinforced fiber bundle formed by impregnating a compound (B) of 13-50 mass% which is expressed by a specific structural formula and satisfies a specific condition into a reinforced fiber bundle (A) of 50-87 mass% includes: the step (I) of supplying the component (B) to the component(A) and bringing the component (B) into contact with the component (A) in a 100-300°C molten state; and the step (II) of heating the component (A) which is in contact with the component (B) to impregnate 80-100 mass% of a supply amount of the component (B) into the component (A). In the molding material, thermoplastic resin (C) is adhered to the composite reinforced fiber bundle manufactured by the method.

Description

  The present invention relates to a method for producing a composite reinforcing fiber bundle and a molding material using the same. More specifically, a method for producing a composite reinforcing fiber bundle having good resin impregnation into the reinforcing fiber bundle and having a small amount of voids and a low volatile content during molding can be obtained. It relates to molding materials.

  Molding materials composed of reinforcing fibers and thermoplastic resins are widely used in sports equipment applications, aerospace applications and general industrial applications because they are lightweight and have excellent mechanical properties. The reinforcing fibers used in these molding materials reinforce the molded product in various forms depending on the usage. These reinforcing fibers include metal fibers such as aluminum fibers and stainless fibers, organic fibers such as aramid fibers and PBO fibers, inorganic fibers such as silicon carbide fibers, and carbon fibers. Carbon fibers are preferred from the viewpoint of the balance between rigidity and lightness, and among them, polyacrylonitrile-based carbon fibers are suitably used.

  Further, various forms such as thermoplastic prepregs, yarns, and glass mats (GMT) are known as molding materials having a continuous reinforcing fiber bundle and a thermoplastic resin as a matrix. Such a molding material makes use of the properties of the thermoplastic resin to facilitate molding, does not require a storage load like a thermosetting resin, and the resulting molded product has high toughness and excellent recyclability. There are features. In particular, a molding material processed into a pellet can be applied to a molding method having excellent economic efficiency and productivity such as injection molding and stamping molding, and is useful as an industrial material.

  However, in the process of manufacturing a molding material, impregnating a continuous reinforcing fiber bundle with a thermoplastic resin has a problem in terms of economy and productivity and is not widely used. For example, it is well known that the higher the melt viscosity of the resin, the more difficult the impregnation of the reinforcing fiber bundle is. Thermoplastic resins with excellent mechanical properties such as toughness and elongation are high molecular weight polymers and require high process temperatures, making them unsuitable for producing molding materials easily and with high productivity. It was. Therefore, a method of kneading with a thermoplastic resin using a composite reinforcing fiber bundle impregnated with a low molecular weight compound has been used for ease of impregnation.

  Patent Document 1 discloses a sizing agent-treated metal-coated carbon fiber chopped strand containing 2 to 40% by mass of a styrene / methyl methacrylate copolymer resin, and dissolving the styrene / methyl methacrylate copolymer resin in a solvent. It is disclosed that a metal-coated carbon fiber strand is introduced into a solution of a sizing agent that has been allowed to dry and dried. The obtained chopped strand has a property that fibers can be stably supplied to the molding machine without being dispersed during dry blending, and the fibers can be easily dispersed in the molding machine. Patent Document 2 discloses that a chopped fiber of a high elastic modulus fiber is immersed in a thermosetting resin solution to impregnate the chopped fiber with a resin solution, and the impregnated chopped fiber is separated, and then is immersed in an aqueous medium. Stir to disperse the impregnated chopped fiber and remove the solvent from the resin solution impregnated in the chopped fiber into the aqueous medium, and then separate and dry the chopped fiber coated with the resin after desolvation from the aqueous medium Thus, a method of coating high-modulus fiber chopped fibers is disclosed. Here, as the thermosetting resin, a novolac type phenol resin is used. However, since both Patent Documents 1 and 2 use a sizing agent dissolved in a solvent, the solvent tends to remain inside the reinforcing fiber bundle, and voids inside the reinforcing fiber bundle tend to be generated, and the drying is difficult. If it is used as a molding material with an insufficient amount, it is not preferable because it may have a large amount of volatile components during molding or may cause defects in the molded product. Moreover, in order to perform sufficient drying, it is difficult to improve a line speed, and it may be inferior from the surface of economical efficiency and productivity.

  Under such circumstances, there has been a demand for the development of a method for producing a composite reinforcing fiber bundle that has good impregnation into the reinforcing fiber bundle and has less voids, and a molding material that has a low volatile content during molding.

JP-A-6-322665 Japanese Patent Publication No. 64-202

  An object of the present invention is to manufacture a composite reinforcing fiber bundle that has good impregnation into a reinforcing fiber bundle, has few voids, and has a small amount of volatile components during molding. In addition, in view of the problems of the prior art, the present invention provides a molding material using a composite reinforcing fiber bundle and capable of producing a molded product having good fiber dispersion in the molded product. With the goal.

  As a result of intensive studies, the present inventors have invented the following method for producing a composite reinforcing fiber bundle that can solve the above problems. That is, a composite reinforcing fiber bundle obtained by impregnating a reinforcing fiber bundle (A) 50 to 87% by mass with a compound (B) 13 to 50% by mass represented by the following structural formula (1) and satisfying the condition (1). A production method comprising supplying component (B) to component (A) and bringing component (B) into contact with component (A) in a molten state at 100 to 300 ° C .; component (B); It is a manufacturing method of the composite reinforcing fiber bundle which has the process (II) which heats the component (A) which is contacting and impregnates the component (A) with 80-100 mass% of the supply amount of a component (B).

(X in Formula (1) is a residue of bisphenols, and a plurality of X may be the same or different. Y is a functional group selected from a hydrogen atom and a glycidyl group, and a plurality of Y are (The average degree of polymerization n is the number of repeating units, and n ≧ 0.)
Condition (1): The melt viscosity at 200 ° C. is 0.01 to 10 Pa · s, and the rate of change in melt viscosity after heating at 200 ° C. for 2 hours is 2 or less.

  In addition, as a result of intensive studies, the present inventors have invented the following molding material that can solve the above-described problems. That is, it is a molding material in which the thermoplastic resin (C) is bonded to the composite reinforcing fiber bundle produced by the above-described method.

  According to the method for producing a composite reinforcing fiber bundle of the present invention, a composite reinforcing fiber bundle having good impregnation into the reinforcing fiber bundle, less voids, and low volatile content during molding can be obtained. Moreover, if the molding material according to the present invention is used, a molded product in which the reinforcing fibers are well dispersed in the molded product can be produced. A molded product molded using the molding material of the present invention is extremely useful for various parts and members such as electrical / electronic equipment, OA equipment, home appliances, automobile parts, internal members, and housings.

It is the schematic which shows an example of the cross-sectional form of the composite reinforcing fiber bundle obtained by this invention. It is the schematic which shows an example of the preferable longitudinal cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable longitudinal cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable longitudinal cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable longitudinal cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable longitudinal cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable cross-sectional form of the molding material of this invention. It is the schematic which shows an example of the preferable cross-sectional form of the molding material of this invention.

  The present invention is a method for producing a composite reinforcing fiber bundle comprising a reinforcing fiber bundle (A) and a resin composition containing a compound (B) represented by the formula (1). First, these components will be described. In the present invention, the composite reinforcing fiber bundle refers to a fiber obtained by impregnating a reinforcing fiber bundle with a compound having affinity with a thermoplastic resin (hereinafter also referred to as an impregnated compound). It is suitably used in combination.

  The reinforcing fiber constituting the component (A) used in the present invention is not particularly limited, but for example, high strength such as carbon fiber, glass fiber, aramid fiber, alumina fiber, silicon carbide fiber, boron fiber, metal fiber, High elastic modulus fibers can be used, and these may be used alone or in combination of two or more. Among these, PAN-based, pitch-based and rayon-based carbon fibers are preferable from the viewpoint of improving the mechanical properties and reducing the weight of the molded product, and from the viewpoint of the balance between the strength and elastic modulus of the molded product obtained. More preferred are fibers. For the purpose of imparting conductivity, reinforcing fibers coated with a metal such as nickel, copper, or ytterbium can also be used.

  Further, as the carbon fiber, the surface oxygen concentration ratio [O / C], which is the ratio of the number of atoms of oxygen (O) and carbon (C) on the fiber surface measured by X-ray photoelectron spectroscopy, is 0.05-0. 5 is preferable, more preferably 0.08 to 0.4, and still more preferably 0.1 to 0.3. When the surface oxygen concentration ratio is 0.05 or more, the functional group amount on the surface of the carbon fiber can be secured, and a stronger adhesion to the thermoplastic resin can be obtained. Moreover, although there is no restriction | limiting in particular in the upper limit of surface oxygen concentration ratio, Generally it can be illustrated to 0.5 or less from the balance of the handleability of carbon fiber, and productivity.

The surface oxygen concentration ratio of the carbon fiber is determined by X-ray photoelectron spectroscopy according to the following procedure. First, after cutting the carbon fiber bundle from which the sizing agent and the like adhering to the carbon fiber surface with a solvent was cut to 20 mm and spreading and arranging on a copper sample support base, using A1Kα1,2 as the X-ray source, The sample chamber is maintained at 1 × 10 ⁸ Torr. The kinetic energy value (KE) of the main peak of C _1s is adjusted to 1202 eV as a peak correction value associated with charging during measurement. C _1s peak area E. Is obtained by drawing a straight base line in the range of 1191 to 1205 eV. O _1s peak area E. Is obtained by drawing a straight base line in the range of 947 to 959 eV.

Here, the surface oxygen concentration ratio is calculated as an atomic number ratio from the ratio of the O _1s peak area to the C _1s peak area using a sensitivity correction value unique to the apparatus. When the model ES-200 manufactured by Kokusai Electric Inc. is used as the X-ray photoelectron spectroscopy apparatus, the sensitivity correction value is set to 1.74.

  The means for controlling the surface oxygen concentration ratio [O / C] to 0.05 to 0.5 is not particularly limited. For example, techniques such as electrolytic oxidation, chemical oxidation, and vapor phase oxidation are used. Among these, electrolytic oxidation treatment is preferable.

  The average fiber diameter of the reinforcing fibers is not particularly limited, but is preferably in the range of 1 to 20 μm and in the range of 3 to 15 μm from the viewpoint of mechanical properties and surface appearance of the obtained molded product. More preferred.

  There is no restriction | limiting in particular in the number of single fibers of a reinforced fiber bundle, It can use within the range of 100-350,000, It is preferable to use within the range of 1,000-250,000 especially. Further, according to the present invention, even a reinforcing fiber bundle having a large number of single fibers can be obtained in a range of 20,000 to 100,000 since a sufficiently impregnated composite reinforcing fiber bundle can be obtained. It is also preferable from the viewpoint of productivity.

  In addition, the component (A) is provided with a sizing agent, which improves the bundling property, bending resistance and scratch resistance, and can suppress the occurrence of fluff and yarn breakage in a higher processing step. As a sizing agent, higher workability can be improved, which is preferable. In particular, in the case of carbon fiber, by applying a sizing agent, it is possible to improve the adhesion and composite overall characteristics by adapting to the surface characteristics such as functional groups on the surface of the carbon fiber.

  Although the adhesion amount of a sizing agent is not specifically limited, 0.01-10 mass% or less is preferable with respect to the mass of only a reinforced fiber, 0.05-5 mass% or less is more preferable, 0.1-2 mass % Or less is more preferable. If the amount is less than 0.01% by mass, the effect of improving adhesiveness is hardly exhibited, and if the amount of adhesion exceeds 10% by mass, the physical properties of the matrix resin may be lowered.

  Furthermore, when the component (A) is provided with a sizing agent, the mass ratio of the sizing agent to the component (B) is preferably 0.001 to 0.5 / 1. More preferably, it is 0.005-0.1 / 1, More preferably, it is 0.01-0.05 / 1. Use of each component within the range is preferable because the interfacial adhesiveness, fiber dispersibility, and mechanical properties can be improved in a balanced manner.

  Examples of the sizing agent include an epoxy resin, a phenol resin, polyethylene glycol, polyurethane, polyester, an emulsifier, and a surfactant. Moreover, these may use together 1 type, or 2 or more types.

  Moreover, it is preferable that the epoxy equivalent or hydroxyl equivalent of a sizing agent is smaller than the epoxy equivalent or hydroxyl equivalent of a component (B). Here, the small epoxy equivalent or hydroxyl equivalent means that the number of epoxy groups or hydroxyl groups per molecular weight is large. By making the epoxy equivalent or hydroxyl equivalent of the sizing agent smaller than the epoxy equivalent or hydroxyl equivalent of the component (B), the interfacial adhesion, fiber dispersibility, and mechanical properties can be improved in a well-balanced manner.

  Examples of the epoxy resin include bisphenol A type epoxy resin, bisphenol F type epoxy resin, aliphatic epoxy resin, phenol novolac type epoxy resin, and the like. Among these, an aliphatic epoxy resin that easily exhibits adhesiveness with the matrix resin is preferable. In general, when an epoxy resin has a large number of epoxy groups, the crosslinking density after the crosslinking reaction becomes high, and therefore it tends to be a structure with low toughness, and even if it exists between the reinforcing fiber and the matrix resin, it is fragile. It is easy to peel off and the strength of the fiber reinforced composite material may not be expressed. On the other hand, since the aliphatic epoxy resin has a flexible skeleton, it tends to have a high toughness structure even if the crosslinking density is high. When it exists between a reinforced fiber and matrix resin, in order to make it soft and it is hard to peel, it is easy to improve the intensity | strength of a fiber reinforced composite material, and preferable.

  Specific examples of the aliphatic epoxy resin include, for example, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, 1,4-diglycidyl ether compound, and 1,4- Examples include butanediol diglycidyl ether, neopentyl glycol diglycidyl ether, polytetramethylene glycol diglycidyl ether, and polyalkylene glycol diglycidyl ether. Also, in the polyglycidyl ether compound, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyglycerol polyglycidyl ether, sorbitol polyglycidyl ether, arabitol polyglycidyl ether, trimethylolpropane polyglycidyl ether, trimethylolpropane Examples thereof include glycidyl ethers, pentaerythritol polyglycidyl ethers, polyglycidyl ethers of aliphatic polyhydric alcohols, and the like.

  Among the aliphatic epoxy resins, it is preferable to use a trifunctional or higher polyfunctional aliphatic epoxy resin, and it is more preferable to use an aliphatic polyglycidyl ether compound having three or more highly reactive glycidyl groups. . Among these, glycerol polyglycidyl ether, diglycerol polyglycidyl ether, polyethylene glycol glycidyl ether, and polypropylene glycol glycidyl ether are more preferable. Aliphatic polyglycidyl ether compounds are preferred because they have a good balance of flexibility, crosslink density, and compatibility with the matrix resin and effectively improve adhesion.

  The means for applying the sizing agent is not particularly limited. For example, there are a method of immersing in a sizing liquid through a roller, a method of contacting a roller to which the sizing liquid is adhered, and a method of spraying the sizing liquid in a mist form. . Moreover, although either a batch type or a continuous type may be sufficient, the continuous type which has good productivity and small variations is preferable. At this time, it is preferable to control the sizing solution concentration, temperature, yarn tension, and the like so that the amount of the sizing agent active ingredient attached to the carbon fiber is uniformly attached within an appropriate range. Moreover, it is more preferable to vibrate the carbon fiber with ultrasonic waves when applying the sizing agent.

  The drying temperature and drying time should be adjusted according to the amount of the compound attached, but the time required for complete removal of the solvent used to apply the sizing agent and drying is shortened, while the thermal deterioration of the sizing agent is prevented and sizing is performed. From the viewpoint of preventing the component (A) formed of the treated carbon fiber from becoming hard and deteriorating the spreadability of the bundle, the drying temperature is preferably 150 ° C. or higher and 350 ° C. or lower. It is more preferable that the temperature is not lower than 250 ° C.

  Examples of the solvent used for the sizing agent include water, methanol, ethanol, dimethylformamide, dimethylallylacetamide, and acetone. Water is preferable from the viewpoint of easy handling and disaster prevention. Accordingly, when a compound insoluble or hardly soluble in water is used as a sizing agent, it is preferable to add an emulsifier and a surfactant and disperse in water. Specifically, as an emulsifier and a surfactant, styrene-maleic anhydride copolymer, olefin-maleic anhydride copolymer, formalin condensate of naphthalene sulfonate, anionic emulsifier such as sodium polyacrylate, Nonionic emulsifiers such as cationic emulsifiers such as polyethyleneimine and polyvinylimidazoline, nonylphenol ethylene oxide adducts, polyvinyl alcohol, polyoxyethylene ether ester copolymers, sorbitan ester ethyl oxide adducts, etc. can be used. A nonionic emulsifier having a small size is preferable because it hardly inhibits the adhesive effect of the polyfunctional compound.

  Such a reinforcing fiber bundle (A) is impregnated with a compound (B) represented by the following formula (1) as an impregnated compound to form a composite reinforcing fiber bundle.

  Here, X in Formula (1) is a residue of bisphenols, and a plurality of X may be the same or different. Examples of bisphenols include bisphenol A type, bisphenol F type, bisphenol AD type, bisphenol S type, alkyl substituted products of these bisphenols, hydrogenated products, and the like. Among them, bisphenol A type and bisphenol F type are preferable because of a good balance between viscosity and heat resistance. Y is a functional group selected from a hydrogen atom and a glycidyl group. A functional group selected from a hydrogen atom and a glycidyl group is preferable because it is easily compatible with the reinforcing fiber and easily impregnated, and can easily improve the dispersibility of the reinforcing fiber during molding. The plurality of Y may be the same or different, but the same is preferable because the viscosity stability of the resin is easily maintained. The average degree of polymerization n is the number of repeating units, and n ≧ 0.

  Moreover, you may mix an additive with a compound (B) in the range which does not impair the objective of this invention. Examples of additives include thermosetting resins, thermoplastic resins, or inorganic fillers, flame retardants, conductivity imparting agents, crystal nucleating agents, ultraviolet absorbers, antioxidants, vibration damping agents, antibacterial agents, insect repellents Agents, deodorants, anti-coloring agents, heat stabilizers, mold release agents, antistatic agents, plasticizers, lubricants, colorants, pigments, dyes, foaming agents, antifoaming agents, or coupling agents.

  In the present invention, the component (B) needs to have a melt viscosity of 0.01 to 10 Pa · s at 200 ° C. Preferably it is 0.05-5 Pa.s, More preferably, it is 0.1-2 Pa.s. When the melt viscosity at 200 ° C. is less than 0.01 Pa · s, the mechanical strength of the component (B) is low, so the mechanical properties of the molded product are impaired. When the melt viscosity exceeds 10 Pa · s, the viscosity of the component (B) is It is high and cannot be impregnated into the component (A). When molding or kneading using the composite reinforcing fiber bundle obtained in the present invention, the component (B) is reduced in the component (B) by reducing the melt viscosity of the component (B). It flows in the mixture of the component (C) and becomes easy to move.

The component (B) needs to have a melt viscosity change rate of 2 or less after heating at 200 ° C. for 2 hours. Here, the melt viscosity change rate is obtained from the following equation.
Viscosity change rate = melt viscosity at 200 ° C. after heating for 2 hours at 200 ° C./melt viscosity at 200 ° C. before heating for 2 hours at 200 ° C.

  Such a rate of change in melt viscosity is preferably 1.5 or less, and more preferably 1.3 or less. When the rate of change in melt viscosity after heating at 200 ° C. for 2 hours exceeds 2, when a composite reinforcing fiber bundle is produced over a long period of time, production stability cannot be ensured and uneven adhesion occurs. By making the melt viscosity change rate 2 or less, stable production of the composite reinforcing fiber bundle can be secured.

  The component (B) preferably has a heating loss at 300 ° C. of 10 ° C./min temperature rise (in air) of 5% or less. More preferably, it is 3% or less. When the loss on heating exceeds 5%, decomposition gas tends to be generated during the impregnation, which may result in a void inside the reinforcing fiber bundle. Moreover, there are many volatile components at the time of shaping | molding using the obtained composite reinforcing fiber bundle, and it may become a defect inside a molded article.

  Moreover, when Y in Formula (1) of a component (B) is a hydrogen atom, it is preferable that a hydroxyl group equivalent is 200-2000 g / eq. More preferably, it is 300-1800 g / eq, More preferably, it is 500-1500 g / eq. When the hydroxyl group equivalent is less than 200 g / eq, the reactivity is high, and self-reaction and reaction with reinforcing fibers and matrix resin occur during molding processing, which may hinder fiber dispersibility. In addition, when the hydroxyl group equivalent exceeds 2000 g / eq, the interaction with the reinforcing fiber bundle is small, so that it is difficult to become familiar with the reinforcing fiber at the time of impregnation and not easily impregnated, and the fiber dispersion becomes insufficient at the time of molding processing. there is a possibility. When the hydroxyl equivalent is 200 to 2000 g / eq, the fiber dispersibility during the molding process can be sufficiently secured.

  Moreover, when Y in Formula (1) of a component (B) is a glycidyl group, it is preferable that an epoxy equivalent is 300-3000 g / eq. More preferably, it is 500-2000 g / eq, More preferably, it is 800-1500 g / eq. When the epoxy equivalent is less than 300 g / eq, the reactivity is high, and a self-reaction or a reaction with a reinforcing fiber or a matrix resin occurs at the time of molding processing, which may hinder fiber dispersibility. In addition, when the epoxy equivalent exceeds 3000 g / eq, the interaction with the reinforcing fiber bundle is small, so that it is difficult to become familiar with the reinforcing fiber during the impregnation and difficult to impregnate, and the fiber dispersion is insufficient during the molding process. there is a possibility. When the epoxy equivalent is 300 to 3000 g / eq, the fiber dispersibility during molding can be sufficiently ensured.

  Moreover, it is preferable that the number average molecular weights of a component (B) are 500-5000. More preferably, it is 800-3000, More preferably, it is 1000-2000. When the number average molecular weight is less than 500, the mechanical strength of the component (B) is low, so the mechanical properties of the molded product may be impaired. On the other hand, when it exceeds 5000, the viscosity of the component (B) increases and the impregnation property may not be improved. When molding or kneading using the composite reinforcing fiber bundle according to the present invention, the number average molecular weight of the component (B) is set to 500 to 5,000 so that the component (B) is the component (A) or (B). And (C) are most likely to flow and move easily in the mixture.

  The number average molecular weight can be measured using gel permeation chromatography (GPC).

  Here, in the method for producing a composite reinforcing fiber bundle according to the present invention, the step of supplying the component (B) to the component (A) and bringing the component (B) into contact with the component (A) in a molten state at 100 to 300 ° C. I) and the step (II) in which the component (A) in contact with the component (B) is heated to impregnate the component (A) with 80 to 100% by mass of the supply amount of the component (B).

  Although it does not specifically limit with process (I), The well-known manufacturing method which provides an oil agent, a sizing agent, and matrix resin to a fiber bundle can be used, Especially, dipping or coating is preferable, and concrete As the coating, a reverse roll, a normal rotation roll, a kiss roll, a spray, and a curtain are preferably used.

  Here, dipping refers to a method in which the component (B) is supplied to the melting bath by a pump and the component (A) is passed through the melting bath. By immersing the component (A) in the melting bath of the component (B), the component (B) can be reliably attached to the component (A). Moreover, a reverse roll, a normal rotation roll, and a kiss roll mean the method of supplying the component (B) fuse | melted with the pump to a roll, and apply | coating the melt of a component (B) to a component (A). Furthermore, the reverse roll is a method in which two rolls rotate in opposite directions to each other and apply the melted component (B) on the roll, and the normal roll has two rolls rotated in the same direction, In this method, the molten component (B) is applied onto a roll. Usually, in the reverse roll and the forward rotation roll, a method is used in which the component (A) is sandwiched, and a roll is further installed so that the component (B) adheres securely. On the other hand, the kiss roll is a method of attaching the component (B) only by contacting the component (A) and the roll. Therefore, the kiss roll is preferably used when the viscosity is relatively low, but by using any roll method, a predetermined amount of the heat-melted component (B) is applied and run while adhering the component (A). Thus, a predetermined amount of the component (B) can be adhered per unit length of the fiber bundle. Spray is a method that uses the principle of spraying, and is a method of spraying molten component (B) into component (A) and spraying it onto component (A). The curtain is applied by letting molten component (B) fall naturally from a small hole. Or a method of applying by overflowing from the melting tank. Since it is easy to adjust the amount required for coating, the loss of component (B) can be reduced.

  Moreover, as a melting temperature at the time of supplying a component (B), 100-300 degreeC is preferable. More preferably, it is 150-250 degreeC. If it is less than 100 degreeC, the viscosity of a component (B) will become high and an adhesion nonuniformity may generate | occur | produce when supplying. Moreover, when it exceeds 300 degreeC, when manufacturing over a long time, a component (B) may thermally decompose. By contacting the component (A) in a molten state at 100 to 300 ° C., the component (B) can be stably supplied.

  Next, as the step (II), the component (A) obtained in the step (I) in contact with the component (B) is heated to make 80 to 100% by mass of the supply amount of the component (B). Impregnation into (A). Specifically, with respect to component (A) in contact with component (B), at a temperature at which component (B) melts, tension is applied with a roll or bar, widening and focusing are repeated, pressure and vibration are applied. In this step, the component (B) is impregnated into the component (A) by an operation such as addition. As a more specific example, there can be mentioned a method of widening by passing the fiber bundle so as to contact the surface of a plurality of heated rolls or bars, among which, a drawing base, a drawing roll, a roll press, a double A method of impregnation using a belt press is preferably used. Here, the squeezing base is a base whose diameter decreases in the direction of travel. The base that promotes impregnation at the same time as scraping off the extra component (B) while converging the reinforcing fiber bundle. It is. Further, the squeeze roll is a roller that promotes impregnation at the same time as scraping off the excessively adhered component (B) by applying tension to the reinforcing fiber bundle with a roller. The roll press is a device that continuously removes the air inside the reinforcing fiber bundle by the pressure between the two rolls and at the same time promotes the impregnation. The double belt press is a device that pushes the belt from above and below the reinforcing fiber bundle. It is a device that promotes impregnation by pressing through.

  In step (II), it is necessary that 80 to 100% by mass of the supply amount of component (B) is impregnated in component (A). Since the yield is directly affected, the higher the yield from the viewpoints of economy and productivity, the better. More preferably, it is 85-100 mass%, More preferably, it is 90-100 mass%. Moreover, if it is less than 80 mass%, not only from an economical viewpoint, but a component (B) may have generated the volatile component in process (II), and a void remains in a component (A) inside. .

  Moreover, in process (II), it is preferable that the maximum temperature of a component (B) is 150-400 degreeC. Preferably it is 180-380 degreeC, More preferably, it is 200 degreeC-350 degreeC. If it is less than 150 degreeC, a component (B) cannot fully be melt | dissolved and it may become a reinforcing fiber bundle with insufficient impregnation. May occur.

  Although it does not specifically limit as a heating method in process (II), Specifically, the method of using a heated chamber and the method of heating and pressurizing simultaneously using a hot roller can be illustrated.

  Moreover, it is preferable to heat in non-oxidizing atmosphere from a viewpoint of suppressing generation | occurrence | production of undesirable side reactions, such as a crosslinking reaction of a component (B), and a decomposition reaction. Here, the non-oxidizing atmosphere is an atmosphere having an oxygen concentration of 5% by volume or less, preferably 2% by volume or less, more preferably an oxygen-free atmosphere, that is, an inert gas atmosphere such as nitrogen, helium or argon. Of these, a nitrogen atmosphere is particularly preferred from the standpoints of economy and ease of handling.

  In addition, the take-up speed of the composite reinforcing fiber bundle directly affects the process speed, so that it is preferably as high as possible from the viewpoints of economy and productivity. Specifically, the take-up speed is preferably 10 to 100 m / min. More preferably, it is 20-100 m / min, More preferably, it is 30-100 m / min. Examples of the pulling method include a method of drawing with a nip roller, a method of winding with a drum winder, and a method of pulling a composite reinforcing fiber bundle while cutting it to a certain length directly with a strand cutter or the like.

  In addition, the component (A) may be opened in advance before the steps (I) and (II). Opening is an operation of separating the converged component (A), and an effect of further enhancing the impregnation property of the component (B) can be expected. With the opening, the thickness of the component (A) is reduced, the width of the component (A) before opening is b1 (mm), the thickness is a1 (μm), and the width of the component (A) after opening is b2 ( mm) and a thickness of a2 (μm), the opening ratio = (b2 / a2) / (b1 / a1) is preferably 2.0 or more, and more preferably 2.5 or more.

  The method for opening component (A) is not particularly limited. For example, a method in which concavo-convex rolls are alternately passed, a method in which drum rolls are used, a method in which tension variation is applied to axial vibration, and a reciprocating motion in the vertical direction 2 A method of changing the tension of the component (A) by the individual friction bodies and a method of blowing air to the component (A) can be used.

  FIG. 1 is a schematic view showing an example of a cross-sectional form of a composite reinforcing fiber bundle obtained by the present invention. In the present invention, the transverse section means a section in a plane orthogonal to the axial direction. The composite reinforcing fiber bundle obtained from the steps (I) and (II) is formed as a composite obtained by applying and impregnating the component (B) to the component (A) (hereinafter, the composite reinforcing fiber bundle is also referred to as a composite). Called). The form of this composite is as shown in FIG. 1, and the component (B) is filled between the single fibers of the component (A). That is, each single fiber of component (A) is dispersed like islands in the sea of component (B).

  In the above composite, the composite (B) is well impregnated with the component (A). For example, when injection molding is performed together with the thermoplastic resin (C), the composite is melt-kneaded in the cylinder of the injection molding machine. , Component (B) diffuses into component (C), helps component (A) disperse in component (C), and at the same time helps component (C) replace and impregnate component (A), It plays the role of so-called impregnation aid and dispersion aid.

  It is preferable that a component (A) is 50-87 mass% per mass of the said composite_body | complex. More preferably, it is 60-85 mass%, More preferably, it is 70-83 mass%. If the component (A) is less than 50% by mass, the resulting molded article may have insufficient mechanical properties, and if it exceeds 87% by mass, the fluidity may be lowered during molding such as injection molding. .

  Moreover, it is preferable that a component (B) is 13-50 mass% per mass of a composite_body | complex. More preferably, it is 15-40 mass%, More preferably, it is 17-30 mass%. If the component (B) is less than 13% by mass, the impregnation property to the inside of the component (A) may be insufficient, and if it exceeds 50% by mass, the mechanical properties of the molded product may be deteriorated.

Further, in the composite, it is desirable that the component (A) is completely impregnated with the component (B). However, in reality, this is difficult, and the composite has a certain amount of voids (component (A) is also included in the component). (B) also does not exist). In particular, when the content of component (A) is large, the number of voids increases, but even when a certain amount of voids are present, the effect of promoting impregnation and fiber dispersion of the present invention is shown. However, if the porosity exceeds 40%, the effect of promoting impregnation and fiber dispersion is remarkably reduced, so the porosity is preferably less than 40%. A more preferable range of the porosity is 20% or less. The porosity is measured by measuring the composite according to the ASTM D2734 (1997) test method, or in the cross section of the composite, the total area of the composite formed by the component (A) and the component (B) and the total of the void. It can be calculated from the area using the following formula.
Porosity (%) = total area of void part / (total area of composite part + total area of void part) × 100.

  Furthermore, the smaller the volatile content of the obtained composite, the smaller the volatile content during molding, which is preferable. The weight loss after drying at 200 ° C. for 2 hours is preferably less than 5%, more preferably less than 3%, and even more preferably less than 1%.

  The composite may be configured to be cut to a length in the range of 1 to 50 mm. By adjusting to the above length, the fluidity and handleability during molding can be sufficiently enhanced. A particularly preferred embodiment of the composite reinforcing fiber bundle that is cut into an appropriate length in this way can be exemplified by chopped strands for injection molding. Since the component (A) is focused by the component (B), it may be used by compounding with the thermoplastic resin (C), or may be dry blended and directly injection molded. Moreover, it can be used depending on the molding method even if it is continuous or long.

  The component (C) used in the present invention is not particularly limited, but polycarbonate resin, styrene resin, polyamide resin, polyester resin, polyphenylene sulfide resin (PPS resin), modified polyphenylene ether resin (modified PPE resin). ), Polyacetal resin (POM resin), liquid crystal polyester, polyarylate, acrylic resin such as polymethyl methacrylate resin (PMMA), vinyl chloride, polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polysulfone , Polyethersulfone, Polyketone, Polyetherketone, Polyetheretherketone (PEEK) Polyolefin such as polyethylene, polypropylene, modified polyolefin, phenolic resin, phenoxy resin, Ethylene / propylene copolymer, ethylene / 1-butene copolymer, ethylene / propylene / diene copolymer, ethylene / carbon monoxide / diene copolymer, ethylene / ethyl (meth) acrylate copolymer, ethylene / Various elastomers such as glycidyl (meth) acrylate, ethylene / vinyl acetate / glycidyl (meth) acrylate copolymer, polyether ester elastomer, polyether ether elastomer, polyether ester amide elastomer, polyester amide elastomer, polyester ester elastomer These may be used, and one or more of these may be used in combination. In particular, polypropylene resins, polyamide resins, polycarbonate resins, and polyphenylene sulfide resins that are highly versatile are preferable. Of these, polyphenylene sulfide resins are preferred from the viewpoints of heat resistance and chemical resistance.

  Moreover, a component (C) may contain another filler and additive in the range which does not impair the objective of this invention. Examples of these include inorganic fillers, flame retardants, conductivity imparting agents, crystal nucleating agents, ultraviolet absorbers, antioxidants, vibration damping agents, antibacterial agents, insect repellents, deodorants, anti-coloring agents, heat stabilizers. , Release agents, antistatic agents, plasticizers, lubricants, colorants, pigments, dyes, foaming agents, antifoaming agents, or coupling agents.

  The molding material of the present invention is constituted by adhering the component (C) to the composite obtained as described above. In the present invention, the molding material is used when molding a molded product by injection molding or the like. It means the raw material used for.

  In the molding material of the present invention, the composite and the component (C) are appropriately disposed and bonded, and as the disposing step, the molten component (C) is disposed so as to contact the composite. Although it is not particularly limited, more specifically, using a extruder and a coating die for a wire coating method, a method of continuously arranging the component (C) around the composite, a roll The film-like component (C) melt | dissolved using the extruder and T die from one side or both surfaces of the composite flattened by the etc. can be arrange | positioned, and the method of integrating with a roll etc. can be mentioned.

  FIG. 2 is a schematic view showing an example of a preferred longitudinal sectional form of the molding material of the present invention. In the present invention, the longitudinal section means a section in a plane including the axial direction. As shown in FIG. 2, an example of the molding material of the present invention is that the component (A) is arranged substantially parallel to the axial direction of the molding material, and the length of the component (A) is substantially equal to the length of the molding material. Are the same length.

  Here, “arranged substantially in parallel” means that the major axis of the component (A) and the major axis of the molding material are oriented in the same direction, The angle deviation is preferably 20 ° or less, more preferably 10 ° or less, and further preferably 5 ° or less. In addition, “substantially the same length” means that, for example, in a pellet-shaped molding material, the component (A) is cut in the middle of the pellet, or the component (A) significantly shorter than the total length of the pellet is substantially Is not included. In particular, the amount of the component (A) shorter than the total length of the pellet is not specified, but the content of the component (A) having a length of 50% or less of the total length of the pellet is 30% by mass or less. Evaluates that the component (A) significantly shorter than the whole pellet length is substantially not contained. Furthermore, the content of the component (A) having a length of 50% or less of the total length of the pellet is preferably 20% by mass or less. In addition, a pellet full length is the length of the component (A) orientation direction in a pellet. Since the component (A) has a length equivalent to that of the molding material, the reinforcing fiber length in the molded product can be increased, and thus excellent mechanical properties can be obtained.

  3 to 6 each schematically show an example of the longitudinal cross-sectional form of the molding material of the present invention, and FIGS. 7 to 11 schematically show examples of the cross-sectional form of the molding material of the present invention. It is a representation.

  The cross-sectional form of the molding material is not limited to that shown in the figure as long as the component (C) is disposed so as to adhere to the composite composed of the component (A) and the component (B). As shown in 3 to 5, a configuration in which the composite is a core material and is sandwiched and arranged in layers with the component (C) is preferable.

  Moreover, as FIG. 7-9 shows, the structure arrange | positioned at the core sheath structure which makes the composite_body | complex a core structure and the circumference | surroundings coat | covers a component (C) is preferable. Moreover, when arrange | positioning so that a component (C) may coat | cover several composite_body | complexes as shown in FIG. 11, the number of composite_body | complexes is about 2-6.

  The boundary between the composite and the component (C) is bonded, and the component (C) partially enters the part of the composite in the vicinity of the boundary and is compatible with the component (B) constituting the composite Alternatively, the reinforcing fiber may be impregnated.

  The molding material of the present invention is kneaded by a technique such as injection molding or press molding to form a final molded product. From the viewpoint of the handling property of the molding material, it is important that the composite and the component (C) are not separated while being bonded until the molding is performed, and the shape as described above is maintained. The composite and component (C) are completely different in shape (size, aspect ratio), specific gravity, and mass, so they are classified at the time of transporting, handling, and transferring materials in the molding process. In some cases, the fluidity may be lowered, the mold may be clogged, and blocking may occur in the molding process.

  From such a viewpoint, the configuration arranged in the core-sheath structure as illustrated in FIGS. If it is such arrangement | positioning, a component (C) will restrain a composite_body | complex and a firm composite can be performed. In addition, as to which of the core-sheath structure as illustrated in FIGS. 7 to 9 or the layered arrangement as illustrated in FIG. From the viewpoint of ease, a core-sheath structure is more preferable.

  The molding material of the present invention may be continuous as long as it has substantially the same cross-sectional shape in the axial direction, and depending on the molding method, a continuous material is cut into a certain length. May be. Preferably, it is cut into a length in the range of 1 to 50 mm. By adjusting to this length, the fluidity and handleability during molding can be sufficiently enhanced. A particularly preferred embodiment of the molding material cut into an appropriate length in this way can be exemplified by long fiber pellets for injection molding.

  Further, the molding material of the present invention can be used depending on the molding method even if it is continuous or long. For example, as a thermoplastic yarn prepreg, it can be wound around a mandrel while heating to obtain a roll-shaped molded product. Examples of such molded products include liquefied natural gas tanks. Moreover, it is also possible to produce a unidirectional thermoplastic prepreg by heating and fusing a plurality of molding materials of the present invention while keeping them continuous in one direction. Such a prepreg can be applied to fields where lightness, high strength, elastic modulus, and impact resistance are required, such as automobile members.

  Further, the proportion of the component (C) in the molding material is 5 to 98.98% by mass, preferably 25 to 94% by mass, more preferably 50 to 88% by mass. A molded product having excellent characteristics can be obtained.

  The molding method of the molding material obtained in the present invention is not particularly limited, but can be applied to molding methods having excellent productivity such as injection molding, autoclave molding, press molding, filament winding molding, stamping molding, etc. It can also be used. Also, integrated molding such as insert molding and outsert molding can be easily performed. Furthermore, it is possible to utilize an adhesive method having excellent productivity such as a correction treatment by heating, heat welding, vibration welding, ultrasonic welding, etc. after molding.

  Molded products obtained by the above molding methods include instrument panels, door beams, under covers, lamp housings, pedal housings, radiator supports, spare tire covers, front end and other various modules, cylinder head covers, bearing retainers, intake manifolds, pedals Aircraft parts such as automobile parts, parts and skins, landing gear pods, winglets, spoilers, edges, ladders, failings, ribs, etc., parts and skins, tools such as monkeys, wrenches, telephones, facsimiles , VTRs, photocopiers, televisions, microwave ovens, audio equipment, toiletries, laser discs, refrigerators, air conditioners, and other home / office electrical product parts. Further, there may be mentioned a housing used for a personal computer, a mobile phone or the like, or a member for electric / electronic equipment represented by a keyboard support which is a member for supporting a keyboard inside the personal computer. In this invention, when the carbon fiber bundle which has electroconductivity is used as a component (A), in such a member for electrical / electronic devices, since electromagnetic wave shielding property is provided, it is more preferable.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the description of these examples.

  First, a method for measuring various characteristics used in this embodiment will be described.

(1) Number average molecular weight measurement The sample to be measured was measured by gel permeation chromatography (GPC). A GPC column packed with polystyrene cross-linked gel was used. Measurement was performed at 150 ° C. using chloroform as a solvent. The molecular weight was calculated in terms of standard polystyrene.

(2) Melt viscosity measurement, viscosity change rate measurement The sample to be measured was measured with a viscoelasticity meter. The melt viscosity was measured at 200 ° C. at 0.5 Hz using a 40 mm parallel plate. Similarly, the viscosity of the sample to be measured was measured after standing in a hot air dryer at 200 ° C. for 2 hours, and the viscosity change rate was calculated.

(3) Weight loss measurement The sample to be measured was measured by thermogravimetric analysis (TGA). Using a platinum sample pan, measurement was carried out at 10 ° C./min.

(4) Measurement of epoxy equivalent and hydroxyl group equivalent The epoxy equivalent was measured according to the JIS K7236 (2004) test method. The hydroxyl equivalent was measured by oxidation with potassium hydroxide, and the value was converted to the hydroxyl equivalent.

(5) Porosity of composite The porosity (%) of the composite was calculated based on the ASTM D2734 (1997) test method.
Determination of the porosity of the composite was performed according to the following criteria, and A to C were determined to be acceptable.
A: 0 to less than 5% B: 5% to less than 20% C: 20% to less than 40% D: 40% or more

(6) Evaluation of the volatile content of the composite The weight of the composite to be measured was measured before and after being left in a hot air dryer at 200 ° C. for 2 hours, and the weight loss was defined as the volatile content. Moreover, the determination was made according to the following criteria, and A was determined to be acceptable.
A: 0 to less than 5% B: 5% or more and less than 10% C: 10% or more

(7) Fiber dispersibility of molded product A molded product of 100 mm x 100 mm x 2 mm was molded, and the number of undispersed CF bundles present on the front and back surfaces was counted visually. The evaluation was performed on 50 molded products, the fiber dispersibility was determined for the total number based on the following criteria, and A to C were set as acceptable.
A: 1 or less undispersed CF bundle B: 1 or more and less than 5 undispersed CF bundles C: 5 or more and less than 10 undispersed CF bundles D: 10 or more undispersed CF bundles

Reference Example 1 Carbon fiber-1
Spinning, firing treatment, and surface oxidation treatment were carried out from a copolymer containing polyacrylonitrile as a main component to obtain continuous carbon fibers having a total number of 24,000 single fibers. The characteristics of this continuous carbon fiber were as follows.
Single fiber diameter: 7μm
Mass per unit length: 1.6 g / m
Specific gravity: 1.8
Surface oxygen concentration ratio [O / C]: 0.06
Tensile strength: 4600 MPa
Tensile modulus: 220 GPa.

Here, the surface oxygen concentration ratio was determined according to the following procedure by X-ray photoelectron spectroscopy using the carbon fiber after the surface oxidation treatment. First, the carbon fiber bundle was cut to 20 mm, spread and arranged on a copper sample support, and then A1Kα1 and 2 were used as X-ray sources, and the inside of the sample chamber was kept at 1 × 10 ⁸ Torr. The kinetic energy value (KE) of the main peak of C _1s was adjusted to 1202 eV as a peak correction value associated with charging during measurement. C _1s peak area E. As a linear base line in the range of 1191 to 1205 eV. O _1s peak area E. As a linear base line in the range of 947 to 959 eV. The atomic ratio was calculated from the ratio of the O _1s peak area to the C _1s peak area using the sensitivity correction value unique to the apparatus. As an X-ray photoelectron spectroscopy apparatus, model ES-200 manufactured by Kokusai Electric Inc. was used, and the sensitivity correction value was set to 1.74.

Reference Example 2 Carbon fiber-2
Spinning, firing treatment, and surface oxidation treatment were carried out from a copolymer containing polyacrylonitrile as a main component to obtain continuous carbon fibers having a total number of single fibers of 48,000. The characteristics of this continuous carbon fiber were as follows.
Single fiber diameter: 7μm
Mass per unit length: 1.6 g / m
Specific gravity: 1.8
Surface oxygen concentration ratio [O / C]: 0.12
Tensile strength: 4600 MPa
Tensile modulus: 220 GPa.

Reference Example 3. Application of sizing agent A sizing agent mother liquor in which sizing agent is dissolved or dispersed in water is prepared, and the sizing agent is applied to the reinforcing fiber by a method of dipping in the sizing agent mother liquor via a roller, followed by drying at 230 ° C. It was.

Reference Example 4 Composite film A liquid film in which the compound to be impregnated was heated and melted was formed on a roll heated to the coating temperature. A reverse roll was used to form a film having a constant thickness on the roll. The continuous component (A) was passed through the roll while contacting it, thereby depositing the impregnated compound. Next, it passed between 5 sets of 50 mm diameter roll presses in the chamber heated to the impregnation temperature. By this operation, the compound to be impregnated was impregnated to the inside of the fiber bundle to form a composite having a predetermined blending amount.

Reference Example 5 Direct injection molding Reference Example 4 After cooling the composite obtained in the above, it is cut with a cutter to obtain a 7 mm chopped strand, dry blended with the chopped strand and the component (C), and using a J350EIII type injection molding machine manufactured by Nippon Steel Co., Ltd. Test specimens (molded articles) for characteristic evaluation were molded at the cylinder temperature and the mold temperature. Here, the cylinder temperature indicates a part where the composite of the injection molding machine and the component (C) are heated and melted, and the mold temperature indicates the temperature of a mold for injecting a resin for forming a predetermined shape. . The obtained test piece was subjected to a characteristic evaluation test after being left in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours. Next, the obtained test piece for characteristic evaluation (molded product) was evaluated according to the above-described injection molded product evaluation method.

Reference Example 6 Molding material Reference Example 4 The composite obtained in the above is passed through a coating die for electric wire coating method installed at the tip of a Nippon Steel Works TEX-30α type twin screw extruder (screw diameter 30 mm, L / D = 32), The melted component (C) was discharged from the extruder into the die and continuously arranged so as to cover the periphery of the composite. At this time, the amount of the composite and the amount of the component (C) were adjusted so as to obtain a desired reinforcing fiber content. The obtained continuous molding material was cooled and then cut with a cutter to obtain a 7 mm long fiber pellet molding material. Next, the obtained pellet-shaped molding material was molded into a characteristic evaluation test piece (molded product) at a predetermined cylinder temperature and mold temperature using a J350EIII type injection molding machine manufactured by Nippon Steel Co., Ltd. . Here, the cylinder temperature indicates a portion where the molding material of the injection molding machine is heated and melted, and the mold temperature indicates a mold for injecting a resin for forming a predetermined shape. The obtained test piece was subjected to a characteristic evaluation test after being left in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours. Next, the obtained test piece for characteristic evaluation (molded product) was evaluated according to the above-described injection molded product evaluation method.

Example 1
As component (A), carbon fiber-1 obtained according to Reference Example 1 is used, and as impregnated compound, component (B) (B) -1 (Mitsubishi Chemical Corporation bisphenol A type epoxy resin, jER1003) Was used in accordance with Reference Example 4 at a coating temperature of 150 ° C. and an impregnation temperature of 250 ° C. Under the present circumstances, it adjusted so that carbon fiber-1 might be 80 mass% and (B) -1 might be 20 mass% (the compounding quantity of an impregnated compound 20 mass%). Subsequently, according to Reference Example 5, using PPS (manufactured by Toray Industries, Inc., polyphenylene sulfide resin, M2588) as the component (C), at 30% by mass of the complex and 70% by mass of PPS, the cylinder temperature: 320 ° C., A test piece for characteristic evaluation (molded product) was directly injection molded at a mold temperature of 150 ° C. The evaluation results are collectively shown in Table 1.

Example 2
(B) -2 (Mitsubishi Chemical Corporation bisphenol A type epoxy resin, jER1004AF) is used as the impregnated compound, and as the component (C), PC (Idemitsu Co., Ltd. polycarbonate resin, A composite material, a molding material, and a molded product were obtained in the same manner as in Example 1 except that A1900) was used and the cylinder temperature was changed to 300 ° C. and the mold temperature was changed to 120 ° C. The characteristic evaluation results are collectively shown in Table 1.

Example 3
(B) -3 (Mitsubishi Chemical Corporation bisphenol A type epoxy resin, jER1006FS) is used as the impregnated compound, and PA66 (Toray Industries, Inc. polyamide resin, A composite, a molding material, and a molded product were obtained in the same manner as in Example 1 except that CM3007) was used. The characteristic evaluation results are collectively shown in Table 1.

Example 4
As component (A), carbon fiber-1 obtained according to Reference Example 1 was used, and as an impregnated compound, component (B) (B) -4 (bisphenol A type phenol resin manufactured by Nippon Steel Chemical Co., Ltd., ZX767) was used to obtain a composite according to Reference Example 4 at a coating temperature of 150 ° C. and an impregnation temperature of 250 ° C. Under the present circumstances, it adjusted so that carbon fiber-1 might be 80 mass% and (B) -4 might be 20 mass% (the compounding quantity of an impregnated compound 20 mass%). Next, according to Reference Example 6, using PPS (manufactured by Toray Industries, Inc., polyphenylene sulfide resin, M2588) as a component (C), a molding material in the form of long fiber pellets is produced at 320 ° C. in the die, The amount of the composite was adjusted to 30% by mass and the amount of PPS was adjusted to 70% by mass. The obtained long fiber pellets were injection-molded with test pieces (molded articles) for property evaluation at a cylinder temperature of 320 ° C. and a mold temperature of 150 ° C. The evaluation results are collectively shown in Table 1.

Example 5
In the same manner as in Example 4, except that (B) -5 (Bisphenol A type phenol resin, ZX798P manufactured by Nippon Steel Chemical Co., Ltd.), which is component (B), was used as the impregnated compound, Materials and molded products were obtained. The characteristic evaluation results are collectively shown in Table 1.

Example 6
Ingredient (A) was attached to carbon fiber-1 at an amount of 1.0 mass% according to Reference Example 3 using glycerol triglycidyl ether (hereinafter referred to as (a) -1) as a sizing agent. By changing to a reinforcing fiber bundle and using (B) -6 (Mitsubishi Chemical Corporation bisphenol F type epoxy resin, jER4004P) as the impregnated compound as the impregnated compound, the blending amount of (B) -6 is A composite, a molding material, and a molded product were obtained in the same manner as in Example 4 except that the content was adjusted to 45% by mass. The characteristic evaluation results are collectively shown in Table 1.

Example 7
A composite, a molding material, and a molded product were obtained in the same manner as in Example 6 except that the blending amount of (B) -6 was adjusted to 15% by mass. The characteristic evaluation results are collectively shown in Table 1.

Example 8
In obtaining the composite, the composite, molding material, and the like, except that the blending amount of (B) -6 was changed to 20% by mass and the application temperature was 250 ° C. and the impregnation temperature was 350 ° C. A molded product was obtained. The characteristic evaluation results are collectively shown in Table 1.

Example 9
The adhesion amount of the sizing agent in the component (A) is changed to 0.4% by mass, the blending amount of (B) -6 is changed to 20% by mass, and the composite amount in the long fiber pellet (molding material) is 20% by mass. %, The amount of PPS was adjusted to 80% by mass, and a composite, a molding material, and a molded product were obtained in the same manner as in Example 6. The characteristic evaluation results are collectively shown in Table 1.

Example 10
Using component (A) as a sizing agent, (a) -1 was used and changed to a reinforcing fiber bundle adhered to carbon fiber-2 at an adhesion amount of 2.0% by mass according to Reference Example 3, and (B) -6 was changed to 20% by mass, the amount of the composite in the long fiber pellet was adjusted to 60% by mass, and the amount of PPS was adjusted to 40% by mass in the same manner as in Example 6, A molded product was obtained. The characteristic evaluation results are collectively shown in Table 1.

Example 11
A composite, a molding material and a molded product were obtained in the same manner as in Example 1 except that the impregnation temperature was changed to 100 ° C. The characteristic evaluation results are collectively shown in Table 1.

Example 12
A composite, a molding material, and a molded product were obtained in the same manner as in Example 1 except that the impregnation temperature was changed to 450 ° C. The characteristic evaluation results are collectively shown in Table 1.

Example 13
A composite, a molding material, and a molded product were obtained in the same manner as in Example 1 except that the take-up speed was changed to 5 m / min. The characteristic evaluation results are collectively shown in Table 1.

Example 14
As in Example 1, except that (B) -7 (mixture of bisphenol A type epoxy resin manufactured by Mitsubishi Chemical Corporation, jER828 / jER1006FS = 90/10) as component (B) was used as the impregnated compound. As a result, composites, molding materials, and molded articles were obtained. The characteristic evaluation results are collectively shown in Table 1.

Comparative Example 1
As component (A), carbon fiber-1 was used in accordance with Reference Example 1 and a 7 mm chopped strand was produced by cutting with a cutter without using an impregnated compound. There wasn't. The characteristic evaluation results are collectively shown in Table 2.

Comparative Example 2
In the same manner as in Example 1, except that (D) -1 (Phenoxy resin, YP-50, manufactured by Nippon Steel Co., Ltd.) was used as the impregnated compound instead of (B) -1. A body, a molding material and a molded product were obtained. The characteristic evaluation results are collectively shown in Table 2.

Comparative Example 3
In the same manner as in Example 1 except that (D) -2 (50 mass% NMP solution of (D) -1) was used as the impregnated compound instead of (B) -1, a composite, A molding material and a molded product were obtained. The characteristic evaluation results are collectively shown in Table 2.

Comparative Example 4
A composite, a molding material, and a molded product were obtained in the same manner as in Example 1 except that the blending amount of (B) -1 was adjusted to 5% by mass. The characteristic evaluation results are collectively shown in Table 2.

Comparative Example 5
A composite, a molding material, and a molded product were obtained in the same manner as in Example 1 except that the coating temperature was adjusted to 80 ° C. The characteristic evaluation results are collectively shown in Table 2.

Comparative Example 6
Other than using (D) -2 (a mixture of 95% by mass of (B) -1 and 5% by mass of 2-ethyl-4-ethylimidazole) instead of (B) -1 as the impregnated compound. Were similar to Example 1 to obtain a composite, a molding material and a molded product. The characteristic evaluation results are collectively shown in Table 2.

  As mentioned above, in Examples 1-14, the composite reinforcing fiber bundle with favorable impregnation property and few voids is obtained by the manufacturing method of the composite reinforcing fiber bundle in the present invention. Moreover, the molding material using the obtained composite reinforcing fiber bundle had a low volatile content at the time of molding, and a molding material having good dispersion of the reinforcing fibers in the molded product could be obtained.

  On the other hand, in Comparative Examples 1 to 5, a reinforcing fiber bundle insufficiently impregnated, or even if the impregnation was sufficient, the volatile matter at the time of molding was large, and a good molding material could not be obtained.

  In the method for producing a composite reinforcing fiber bundle of the present invention, a compound having a bisphenol residue is heated and melted and impregnated, so that the impregnation property to the reinforcing fiber bundle is good, there are few voids, and the volatile content during molding is low. A few composite reinforcing fiber bundles can be obtained, and molding materials using the obtained composite reinforcing fiber bundles can obtain molded products with excellent dispersion of reinforcing fibers in molded products, and can be used in various applications. it can. It is particularly suitable for automobile parts, electrical / electronic parts, household / office electrical product parts.

1 Monofilament of reinforcing fiber 2 Compound (B) represented by Formula (1)
3 Composite fiber bundle 4 Thermoplastic resin (C)

Claims (17)

A method for producing a composite reinforcing fiber bundle obtained by impregnating a reinforcing fiber bundle (A) of 50 to 87 mass% with 13 to 50 mass% of a compound (B) represented by the following structural formula (1) and satisfying the condition (1) The step (I) of supplying the component (B) to the component (A) and bringing the component (B) into contact with the component (A) in a molten state at 100 to 300 ° C .; The manufacturing method of the composite reinforcing fiber bundle which has the process (II) which heats the component (A) currently heated and impregnates the component (A) with 80-100 mass% of the supply amount of a component (B).

X in Formula (1) is a residue of bisphenols, and a plurality of X may be the same or different. Y is a functional group selected from a hydrogen atom and a glycidyl group, and a plurality of Y may be the same or different. The average degree of polymerization n is the number of repeating units, and n ≧ 0.
Condition (1): The melt viscosity at 200 ° C. is 0.01 to 10 Pa · s, and the rate of change in melt viscosity after heating at 200 ° C. for 2 hours is 2 or less. The method for producing a composite reinforcing fiber bundle according to claim 1, wherein in the step (I), one kind selected from dipping, reverse roll, forward rotation roll, kiss roll, spray and curtain is used for supplying the component (B). The method for producing a composite reinforcing fiber bundle according to claim 1 or 2, wherein in the step (II), one kind selected from a drawing base, a drawing roll, a roll press, and a double belt press is used for impregnation of the component (B). The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 3, wherein in step (II), the maximum temperature of the component (B) is 150 to 400 ° C. The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 4, wherein the take-up speed of the composite reinforcing fiber bundle is 10 to 100 m / min. The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 5, wherein the component (B) has a heating loss at 300 ° C of 10 ° C / min temperature rise (in air) of 5% or less. The component (B) has a hydroxyl group equivalent of 200 to 2000 g / eq, The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 6. The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 6, wherein the component (B) has an epoxy equivalent of 300 to 3000 g / eq. The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 8, wherein the component (A) is provided with a sizing agent. The method for producing a composite reinforcing fiber bundle according to claim 9, wherein the mass ratio of the sizing agent to the component (B) is 0.001 to 0.5 / 1. The method for producing a composite reinforcing fiber bundle according to claim 9 or 10, wherein an epoxy equivalent or a hydroxyl equivalent of the sizing agent is smaller than an epoxy equivalent or a hydroxyl equivalent of the component (B). The method for producing a composite reinforcing fiber bundle according to any one of claims 1 to 11, wherein the reinforcing fiber bundle is a carbon fiber bundle. The method for producing a composite reinforcing fiber bundle according to claim 12, wherein the number of filaments of the carbon fiber bundle is 20,000 to 100,000. The method for producing a composite reinforcing fiber bundle according to any one of claims 9 to 13, wherein the sizing agent is a trifunctional or higher polyfunctional aliphatic epoxy. The molding material by which the thermoplastic resin (C) is adhere | attached on the composite reinforcing fiber bundle manufactured by the method in any one of Claims 1-14. The molding material according to claim 15, wherein the composite reinforcing fiber bundle has a core structure and a core-sheath structure around which the component (C) is coated. The molding material according to claim 15 or 16, which is cut into a length of 1 to 50 mm.

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