WO2019043843A1 - エポキシ樹脂硬化物、エポキシ樹脂組成物、成形体及び複合材料 - Google Patents
エポキシ樹脂硬化物、エポキシ樹脂組成物、成形体及び複合材料 Download PDFInfo
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- WO2019043843A1 WO2019043843A1 PCT/JP2017/031209 JP2017031209W WO2019043843A1 WO 2019043843 A1 WO2019043843 A1 WO 2019043843A1 JP 2017031209 W JP2017031209 W JP 2017031209W WO 2019043843 A1 WO2019043843 A1 WO 2019043843A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/22—Di-epoxy compounds
- C08G59/24—Di-epoxy compounds carbocyclic
- C08G59/245—Di-epoxy compounds carbocyclic aromatic
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/02—Polycondensates containing more than one epoxy group per molecule
- C08G59/04—Polycondensates containing more than one epoxy group per molecule of polyhydroxy compounds with epihalohydrins or precursors thereof
- C08G59/06—Polycondensates containing more than one epoxy group per molecule of polyhydroxy compounds with epihalohydrins or precursors thereof of polyhydric phenols
- C08G59/066—Polycondensates containing more than one epoxy group per molecule of polyhydroxy compounds with epihalohydrins or precursors thereof of polyhydric phenols with chain extension or advancing agents
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/4007—Curing agents not provided for by the groups C08G59/42 - C08G59/66
- C08G59/4085—Curing agents not provided for by the groups C08G59/42 - C08G59/66 silicon containing compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/50—Amines
- C08G59/5033—Amines aromatic
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/50—Amines
- C08G59/504—Amines containing an atom other than nitrogen belonging to the amine group, carbon and hydrogen
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
- C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
- C08G2650/50—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing nitrogen, e.g. polyetheramines or Jeffamines(r)
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2201/00—Properties
- C08L2201/08—Stabilised against heat, light or radiation or oxydation
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2203/00—Applications
- C08L2203/30—Applications used for thermoforming
Definitions
- the present invention relates to an epoxy resin cured product, an epoxy resin composition, a molded body and a composite material.
- An epoxy resin cured product obtained by curing an epoxy resin is used in various applications utilizing its excellent heat resistance. While a cured epoxy resin product is excellent in heat resistance, it tends to be inferior in fracture toughness as compared with a thermoplastic resin. Then, the method (for example, refer nonpatent literature 1) etc. which add a toughness modifier to an epoxy resin as a method of improving the fracture toughness of an epoxy resin hardened material are proposed.
- the present invention provides an epoxy resin cured product excellent in the balance between fracture toughness and heat resistance, an epoxy resin composition capable of forming the epoxy resin cured product, and a molded article and a composite material containing the epoxy resin cured product. Intended to be provided.
- Means for solving the above problems include the following embodiments.
- a cured product of an epoxy resin having a smectic structure which is a cured product of an epoxy compound having a mesogenic structure and a curing agent having a molecular weight of 100 or more or a flexible skeleton.
- the curing agent has at least two functional groups, and the molecular chain or the flexible skeleton is disposed between one functional group and the other functional group, ⁇ 1> or ⁇
- ⁇ 6> The epoxy resin cured product according to ⁇ 1> or ⁇ 2>, wherein the molecular chain or the flexible skeleton contains at least one selected from the group consisting of an alkylene group, an alkyleneoxy group and a siloxane bond.
- ⁇ 7> The epoxy resin cured product according to ⁇ 1> or ⁇ 2>, or the epoxy resin composition according to any one of ⁇ 3> to ⁇ 6>, wherein the curing agent comprises an amine curing agent.
- ⁇ 8> The epoxy resin cured product according to ⁇ 1> or ⁇ 2>, or the epoxy resin composition according to any one of ⁇ 3> to ⁇ 7>, wherein the curing agent comprises an aromatic amine compound.
- the epoxy resin composition according to any one of ⁇ 3> to ⁇ 10>, wherein the total light transmittance when cured is ⁇ 60>.
- a cured epoxy resin which is a cured product of the epoxy resin composition according to any one of ⁇ 12> ⁇ 3> to ⁇ 11>.
- the composite material as described in ⁇ 14> which has ⁇ 15> at least 1 hardened
- an epoxy resin cured product having excellent balance between fracture toughness and heat resistance, an epoxy resin composition capable of forming the epoxy resin cured product, and a molded article and a composite material containing the epoxy resin cured product.
- the term “step” includes, in addition to steps independent of other steps, such steps as long as the purpose of the step is achieved even if it can not be clearly distinguished from other steps.
- numerical values described before and after “to” are included in the numerical range indicated using “to” as the minimum value and the maximum value, respectively.
- the upper limit value or the lower limit value described in one numerical value range may be replaced with the upper limit value or the lower limit value of the other stepwise description numerical value range in the numerical value range described stepwise in the present disclosure.
- the upper limit value or the lower limit value of the numerical range may be replaced with the value shown in the example.
- each component may contain a plurality of corresponding substances.
- the content or content of each component is the total content or content of the plurality of substances present in the composition unless otherwise specified.
- particles corresponding to each component may contain a plurality of types.
- the particle diameter of each component means the value for the mixture of the plurality of particles present in the composition unless otherwise specified.
- the term “layer” may mean that when the region in which the layer is present is observed, it is formed in only a part of the region, in addition to the case where the region is entirely formed. included.
- “epoxy compound” means a compound having an epoxy group in the molecule.
- Epoxy resin is a concept of capturing a plurality of epoxy compounds as an aggregate, and means an uncured state.
- the epoxy resin cured product (first embodiment) of the present disclosure is a cured product of an epoxy compound having a mesogen structure and a curing agent having a molecular weight of 100 or more or a flexible skeleton (hereinafter also referred to as a specific curing agent). It has a smectic structure.
- the epoxy resin cured product having the above configuration is excellent in the balance between fracture toughness and heat resistance, and is particularly excellent in fracture toughness.
- the reason is not necessarily clear, but first, by using an epoxy compound having a mesogen structure as the epoxy compound, the fracture toughness of the cured epoxy resin product is superior to the case where other epoxy compounds are used.
- the flexible molecular structure possessed by the specific curing agent acts to enhance the fracture toughness of the epoxy resin cured product, and further that the smectic structure formed in the epoxy resin cured product also contributes to the improvement of the fracture toughness. Be done.
- the epoxy resin cured product (second embodiment) of the present disclosure is a cured product of an epoxy compound having a mesogenic structure and a curing agent having a molecular chain having a molecular weight of 100 or more or a flexible skeleton, and does not have a smectic structure. .
- the epoxy resin cured product having the above configuration is excellent in the balance between fracture toughness and heat resistance, and has a certain degree of light transmittance.
- the reason is not necessarily clear, but first, by using an epoxy compound having a mesogen structure as the epoxy compound, the fracture toughness of the cured epoxy resin product is superior to the case where other epoxy compounds are used.
- the flexible molecular structure possessed by the specific curing agent acts to enhance the fracture toughness of the epoxy resin cured product, and the reduction in light transmittance is suppressed because a smectic structure is not formed in the epoxy resin cured product. It is guessed.
- the epoxy resin cured product has optical transparency, it can be expected to expand the application to the field where transparency of optical parts and the like is required.
- examples of the mesogen structure of the “epoxy compound having a mesogenic structure” include biphenyl structure, phenyl benzoate structure, cyclohexyl benzoate structure, azobenzene structure, stilbene structure, terphenyl structure, anthracene structure, derivatives thereof, and these And a structure in which two or more of the mesogenic structures of are linked via a linking group.
- the epoxy compound which has a mesogenic structure has the property that high-order structure is formed in the hardened
- high-order structure means a structure including a high-order structure in which constituent elements are aligned to form a micro-ordered structure, and corresponds to, for example, a crystal phase and a liquid crystal phase.
- the presence or absence of such a higher order structure can be determined by a polarization microscope. That is, in the observation in the cross nicol state, it is possible to distinguish by the fact that interference fringes due to depolarization are observed.
- This higher order structure is usually present in the form of islands in the cured epoxy resin to form a domain structure, and one of the islands corresponds to one higher order structure.
- the components themselves of this higher order structure are generally formed by covalent bonds.
- the higher order structure formed in the epoxy resin cured product includes a nematic structure and a smectic structure.
- the nematic structure and the smectic structure are forms of liquid crystal structures, respectively.
- the nematic structure is a liquid crystal structure in which the molecular long axis is oriented uniformly and has only an orientational order.
- the smectic structure is a liquid crystal structure having a layer structure, having a one-dimensional position order in addition to the alignment order. The order is higher in the smectic structure than in the nematic structure.
- Whether or not a smectic structure is formed in the cured epoxy resin can be determined by X-ray diffraction measurement of the cured product.
- the X-ray diffraction measurement can be performed, for example, using an X-ray diffractometer manufactured by Rigaku Corporation.
- Curing conditions may determine the formation or non-formation of a smectic structure in the epoxy resin cured product.
- a smectic structure is difficult to form when the curing temperature is high, and a smectic structure is easily formed when the curing temperature is low Controlling the curing temperature by utilizing the properties can be mentioned.
- the present disclosure is not limited to this method.
- the epoxy resin cured product of the present disclosure may be obtained by curing an epoxy resin composition described later.
- the fracture toughness value (MPa ⁇ m 1/2 ) of the cured epoxy resin product is not particularly limited, and can be set according to the application of the cured epoxy resin product. For example, preferably greater than 1.8 MPa ⁇ m 1/2, more preferably 1.9 MPa ⁇ m 1/2 or more, more preferably 2.0 MPa ⁇ m 1/2 or more.
- the upper limit of the fracture toughness value is not particularly limited, but from the viewpoint of balance with the glass transition temperature (heat resistance), it is preferably 4.0 MPa ⁇ m 1/2 or less, and 3.7 MPa ⁇ m 1/2 or less It is more preferable that the pressure be 3.5 MPa ⁇ m 1/2 or less.
- the fracture toughness value of the epoxy resin cured product can be calculated, for example, from the result obtained by performing three-point bending measurement according to the method described in the examples to be described later.
- the total light transmittance (%) of the cured epoxy resin product is not particularly limited, and can be set according to the application of the cured epoxy resin product. For example, it is preferable to exceed 60%, more preferably 65% or more, and still more preferably 70% or more.
- the upper limit of the total light transmittance is not particularly limited, but is preferably 95% or less, more preferably 93% or less, and still more preferably 90% or less, in view of the balance with other properties.
- the total light transmittance of the epoxy resin cured product can be measured, for example, according to the method described in the examples described later.
- the glass transition temperature (° C.) of the cured epoxy resin is not particularly limited, and can be set according to the application of the cured epoxy resin. From the viewpoint of heat resistance, the temperature is preferably higher than 120 ° C., more preferably 125 ° C. or higher, and still more preferably 130 ° C. or higher. From the viewpoint of securing good fracture toughness, the temperature is preferably 350 ° C. or less, more preferably 300 ° C. or less, and still more preferably 250 ° C. or less.
- the glass transition temperature of the epoxy resin cured product can be calculated, for example, from the results obtained by performing dynamic viscoelasticity measurement according to the method described in the examples described later.
- the epoxy resin composition of the present disclosure (first embodiment) contains an epoxy compound having a mesogenic structure and a specific curing agent.
- the epoxy resin composition having the above-mentioned configuration can form a cured epoxy resin product which is excellent in the balance between fracture toughness and heat resistance.
- the flexible molecular structure of the specific curing agent acts to enhance the fracture toughness of the epoxy resin cured product.
- the epoxy resin composition of the present disclosure it is possible to obtain a cured epoxy resin having a smectic structure (first embodiment) or to obtain a cured epoxy resin having no smectic structure (a second embodiment). It is.
- the desired epoxy resin cured product can be obtained by changing the curing conditions of the epoxy resin composition. For this reason, according to the epoxy resin composition of the present disclosure, realization of improvement in productivity of a cured epoxy resin product, expansion of usage of the cured epoxy resin product and the like can be expected.
- the epoxy resin composition may contain an epoxy compound which does not correspond to an epoxy compound having a mesogenic structure.
- the proportion of the epoxy compound having a mesogen structure in the entire epoxy resin is preferably 80% by mass or more, and more preferably 90% by mass or more.
- the epoxy resin composition may contain a curing agent that does not correspond to the specific curing agent.
- the ratio of the specific curing agent to the entire curing agent is preferably 80% by mass or more, and more preferably 90% by mass or more.
- the epoxy compound having a mesogen structure contained in the epoxy resin composition may be one kind or two or more kinds.
- the structure of the epoxy compound having a mesogenic structure is not particularly limited, but it is preferable to contain an epoxy compound represented by the following general formula (A).
- X represents a linking group containing at least one selected from Group (I) consisting of the following divalent groups.
- Y is each independently an aliphatic hydrocarbon group having 1 to 8 carbon atoms, an aliphatic alkoxy group having 1 to 8 carbon atoms, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a cyano group, a nitro group or an acetyl group Indicates Each n independently represents an integer of 0 to 4.
- Y independently represents an aliphatic hydrocarbon group having 1 to 8 carbon atoms, an aliphatic alkoxy group having 1 to 8 carbon atoms, a fluorine atom, a chlorine atom, a bromine atom, It shows an iodine atom, a cyano group, a nitro group or an acetyl group.
- n each independently represents an integer of 0 to 4, k represents an integer of 0 to 7, m represents an integer of 0 to 8, and l represents an integer of 0 to 12.
- Y is preferably independently an aliphatic hydrocarbon group having 1 to 8 carbon atoms, and is preferably a methyl group.
- n, k, m and l are each independently 0.
- the epoxy compound having a mesogenic structure may be a compound having a linking group in which X in the general formula (A) includes a divalent group represented by the following structure in group (I).
- the epoxy compound having a mesogen structure may be an epoxy compound having one or more structures represented by the following general formula (I).
- R 1 to R 4 each independently represent a hydrogen atom or an alkyl group having 1 to 3 carbon atoms.
- R 1 to R 4 are each independently preferably a hydrogen atom or an alkyl group having 1 to 2 carbon atoms, more preferably a hydrogen atom or a methyl group, and still more preferably a hydrogen atom.
- 2 to 4 of R 1 to R 4 be a hydrogen atom, more preferably 3 or 4 be a hydrogen atom, and it is further preferable that all 4 be a hydrogen atom.
- one of R 1 to R 4 is an alkyl group having 1 to 3 carbon atoms
- at least one of R 1 and R 4 is preferably an alkyl group having 1 to 3 carbon atoms.
- R 1 ⁇ R 4 in the general formula (M) is the same as the specific examples of R 1 ⁇ R 4 in formula (I), is the same preferred ranges thereof.
- R 1 ⁇ R 4 in formula (II-A) and (II-B) is the same as the specific examples of R 1 ⁇ R 4 in formula (I), it is the same and the preferred ranges thereof .
- Each R 5 independently represents an alkyl group having 1 to 8 carbon atoms, preferably an alkyl group having 1 to 3 carbon atoms, and more preferably a methyl group.
- Each X independently represents -O- or -NH-.
- n independently represents an integer of 0 to 4, preferably an integer of 0 to 2, and more preferably an integer of 0 to 1. Preferably, 0 is more preferred.
- epoxy compound having two structures represented by the general formula (I) at least one selected from the group consisting of epoxy compounds represented by the following general formulas (III-A) to (III to C) is It can be mentioned.
- Formula (III-A) ⁇ definition of R 1 ⁇ R 5, n and X in (III ⁇ C) is formula (II-A) and (II-B) R 1 ⁇ R 5 in, n and X And their preferred ranges are also the same.
- the epoxy compound may include a combination of an epoxy compound having one mesogen structure and an epoxy compound having two or more mesogen structures.
- a combination of an epoxy compound having one structure represented by General Formula (I) and an epoxy compound having two or more structures represented by General Formula (I) may be included.
- the number (one or more) of mesogenic structures means the number of mesogenic structures commonly present in an epoxy compound having one mesogenic structure and an epoxy compound having two or more mesogenic structures. And the existence of mesogenic structures not common to both compounds is not taken into consideration.
- An example of a combination of an epoxy compound having one mesogen structure and an epoxy compound having two or more mesogen structures is obtained by reacting an epoxy compound having one mesogen structure (hereinafter also referred to as an epoxy monomer) with this. And combinations of epoxy compounds (hereinafter also referred to as multimers) having two or more mesogen structures.
- the method of reacting the epoxy monomer to obtain a multimer is not particularly limited.
- a method of synthesis by self-polymerization of an epoxy monomer a method of synthesis by reacting an epoxy monomer and a compound having a functional group capable of reacting with an epoxy group may be mentioned.
- the synthesis conditions are adjusted so that a part of the epoxy monomer remains unreacted in the reaction product, so that the unreacted epoxy monomer and the polymer in the reactant can be obtained. Both may be present.
- the polymer is synthesized by reacting the epoxy monomer with a compound having a functional group capable of reacting with the epoxy group. Method is preferred.
- the method of reacting the epoxy monomer and the compound having a functional group capable of reacting with the epoxy group is not particularly limited. For example, it can be carried out by dissolving an epoxy monomer, a compound having a functional group capable of reacting with an epoxy group, and a reaction catalyst used as needed in a solvent and stirring while heating. Alternatively, for example, it can be carried out by mixing an epoxy monomer, a compound having a functional group capable of reacting with an epoxy group, and a reaction catalyst optionally used without using a solvent and stirring while heating. .
- the type of solvent in the case of using a solvent is a solvent which can dissolve an epoxy monomer and a compound having a functional group capable of reacting with an epoxy group, and can heat up to a temperature necessary for reacting both compounds.
- a solvent which can dissolve an epoxy monomer and a compound having a functional group capable of reacting with an epoxy group, and can heat up to a temperature necessary for reacting both compounds.
- cyclohexanone, cyclopentanone, ethyl lactate, propylene glycol monomethyl ether, N-methyl pyrrolidone, methyl cellosolve, ethyl cellosolve, propylene glycol monopropyl ether and the like can be mentioned.
- the amount of the solvent in the case of using a solvent is not particularly limited as long as it can dissolve the epoxy monomer, the compound having a functional group capable of reacting with the epoxy group, and the reaction catalyst optionally used.
- the solubility varies depending on the type of raw material before reaction, the type of solvent, etc., for example, the viscosity of the solution after reaction will be in a preferable range if it is an amount such that the charged solid concentration becomes 20 mass% to 60 mass%. There is a tendency.
- the type of the compound having a functional group capable of reacting with the epoxy group is not particularly limited.
- the compound having a functional group capable of reacting with an epoxy group is a dihydroxybenzene compound having a structure in which two hydroxyl groups are bonded to one benzene ring, and two amino acids It is preferably at least one selected from the group consisting of diaminobenzene compounds having a structure in which a group is bonded to one benzene ring (hereinafter, also referred to as a specific aromatic compound).
- dihydroxybenzene compounds examples include 1,2-dihydroxybenzene (catechol), 1,3-dihydroxybenzene (resorcinol), 1,4-dihydroxybenzene (hydroquinone), and derivatives thereof.
- diaminobenzene compounds examples include 1,2-diaminobenzene, 1,3-diaminobenzene, 1,4-diaminobenzene, derivatives thereof and the like.
- the derivative of the specific aromatic compound includes a compound in which a substituent such as an alkyl group having 1 to 8 carbon atoms is bonded to the benzene ring of the specific aromatic compound. As the specific aromatic compounds, one type may be used alone, or two or more types may be used in combination.
- the specific aromatic compound is preferably at least one selected from the group consisting of 1,4-dihydroxybenzene and 1,4-diaminobenzene from the viewpoint of the ease of formation of the smectic structure in the epoxy resin cured product.
- the epoxy compound obtained by reacting this with an epoxy monomer tends to have a linear molecular structure. For this reason, it is considered that the stacking property of the molecules is high and it is easy to form a smectic structure in the cured product.
- the type of reaction catalyst is not particularly limited, and an appropriate catalyst can be selected from the viewpoint of reaction rate, reaction temperature, storage stability and the like. Specifically, imidazole compounds, organic phosphorus compounds, tertiary amines, quaternary ammonium salts and the like can be mentioned.
- the reaction catalyst may be used alone or in combination of two or more.
- the reaction catalyst is preferably an organic phosphorus compound.
- the organic phosphorus compound include organic phosphine compounds, compounds having an intramolecular polarization formed by addition of compounds having a ⁇ bond such as maleic anhydride, quinone compounds, diazophenylmethane and phenol resin to organic phosphine compounds, organic A complex of a phosphine compound and an organic boron compound can be mentioned.
- organic phosphine compounds include triphenylphosphine, diphenyl (p-tolyl) phosphine, tris (alkylphenyl) phosphine, tris (alkoxyphenyl) phosphine, tris (alkylalkoxyphenyl) phosphine, tris (dialkylphenyl) phosphine, Tris (trialkylphenyl) phosphine, tris (tetraalkylphenyl) phosphine, tris (dialkoxyphenyl) phosphine, tris (trialkoxyphenyl) phosphine, tris (tetraalkoxyphenyl) phosphine, trialkylphosphine, dialkyl aryl phosphine, alkyl diaryl Phosphine etc. are mentioned.
- quinone compounds include 1,4-benzoquinone, 2,5-toluquinone, 1,4-naphthoquinone, 2,3-dimethylbenzoquinone, 2,6-dimethylbenzoquinone, 2,3-dimethoxy-5-methyl- Examples thereof include 1,4-benzoquinone, 2,3-dimethoxy-1,4-benzoquinone and phenyl-1,4-benzoquinone.
- organoboron compound examples include tetraphenyl borate, tetra-p-tolyl borate, tetra-n-butyl borate and the like.
- the amount of reaction catalyst is not particularly limited. From the viewpoint of reaction rate and storage stability, it is 0.1 parts by mass to 1.5 parts by mass with respect to 100 parts by mass in total of the epoxy monomer and the compound having a functional group capable of reacting with the epoxy group. Is preferable, and 0.2 to 1 part by mass is more preferable.
- the synthesis of the multimer can be carried out using a reaction vessel such as a flask for a small scale and a synthesis pot for a large scale.
- the specific synthesis method is, for example, as follows. First, an epoxy monomer is charged into a reaction vessel, a solvent is added if necessary, and the temperature is raised to the reaction temperature with an oil bath or a heat medium to dissolve the epoxy monomer. A compound having a functional group capable of reacting with an epoxy group is charged therein, and then, if necessary, a reaction catalyst is charged to initiate the reaction. Then, if necessary, the solvent is distilled off under reduced pressure to obtain a multimer-containing reactant.
- the reaction temperature is not particularly limited as long as the reaction between the epoxy group of the epoxy monomer and the functional group capable of reacting with the epoxy group proceeds.
- a range of 100 ° C. to 180 ° C. is preferable, and a range of 100 ° C. to 150 ° C. is more preferable.
- the reaction temperature is 180 ° C. or lower, the possibility of gelation tends to be reduced.
- the compounding ratio may be such that the ratio (A / B) of the number (A) of epoxy groups to the number (B) of functional groups capable of reacting with epoxy groups is in the range of 100/100 to 100/1. From the viewpoint of fracture toughness and heat resistance of the cured product, a compounding ratio in which A / B is in the range of 100/50 to 100/1 is preferable.
- the structure of the multimer may be, for example, the molecular weight of the multimer presumed to be obtained by the reaction of an epoxy monomer used for synthesis with a compound having a functional group capable of reacting with an epoxy group, a UV and a mass spectrum detector. It can determine by collating with the molecular weight of the object compound calculated
- the weight average molecular weight (Mw) of the epoxy resin is not particularly limited, and can be selected according to the desired properties of the epoxy resin.
- the specific curing agent is not particularly limited as long as it is a compound capable of causing a curing reaction with the epoxy resin contained in the epoxy resin composition.
- amine curing agents, phenol curing agents, acid anhydride curing agents, polymercaptan curing agents, polyaminoamide curing agents, isocyanate curing agents, blocked isocyanate curing agents and the like can be mentioned.
- the specific curing agent may be used alone or in combination of two or more.
- the specific curing agent is preferably an amine curing agent having an amino group as a functional group that reacts with an epoxy group, or a phenol curing agent having a hydroxyl group as a functional group that reacts with an epoxy group, and the heat-resistant epoxy resin cured product From the viewpoint of amine curing agents are more preferred. From the viewpoint of controlling the curing reaction time, the compound (aromatic amine compound) having an aromatic ring to which an amino group is bonded is more preferable. As an aromatic ring, a benzene ring and a naphthalene ring are mentioned as a preferable example.
- the molecular weight of the molecular chain having a specific curing agent of 100 or more is preferably 110 or more, and more preferably 120 or more.
- the upper limit of the molecular weight of the molecular chain is not particularly limited, but is preferably 10000 or less, more preferably 5000 or less from the viewpoint of the glass transition temperature.
- the molecular weight of the flexible skeleton possessed by the specific curing agent is preferably 100 or more, more preferably 110 or more, and still more preferably 120 or more.
- the upper limit of the molecular weight of the flexible skeleton is not particularly limited, but is preferably 10000 or less, more preferably 5000 or less from the viewpoint of the glass transition temperature.
- the specific curing agent has at least two functional groups, and a molecular chain or a flexible skeleton having a molecular weight of 100 or more is disposed between one functional group and the other functional group. Is preferred.
- the specific curing agent has at least two amino groups, and a molecular chain or a flexible backbone having a molecular weight of 100 or more is disposed between one amino group and the other amino group. It may be
- the specific curing agent has at least two aromatic rings to which amino groups are bound, and one of the aromatic rings to which one amino group is bound and the aromatic ring to which the other amino group is bound.
- a molecular chain having a molecular weight of 100 or more or a flexible backbone may be disposed.
- the molecular chain or flexible skeleton having a molecular weight of 100 or more may be linear or branched, but is preferably linear from the viewpoint of improvement in fracture toughness.
- the structure of the molecular chain or flexible backbone having a molecular weight of 100 or more is not particularly limited.
- the structure containing at least 1 sort (s) selected from the group which consists of an alkylene group, an alkylene oxy group, and a siloxane bond is mentioned.
- the type is not particularly limited.
- amine curing agents other than the specific curing agent specifically, 3,3′-diaminodiphenyl sulfone, 4,4′-diaminodiphenyl sulfone, 4,4′-diaminodiphenylmethane, 4,4′-diaminodiphenyl ether, 4,4'-Diamino-3,3'-dimethoxybiphenyl, 4,4'-diaminophenylbenzoate, 1,5-diaminonaphthalene, 1,3-diaminonaphthalene, 1,4-diaminonaphthalene, 1,8-diamino Naphthalene, 1,3-diaminobenzene, 1,4-diaminobenzene, 4,4′-diaminobenzanilide, trimethylene-bis
- the content of the curing agent in the epoxy resin composition is not particularly limited. From the viewpoint of the efficiency of the curing reaction, the number A of functional groups (active hydrogen in the case of an amine curing agent) and the number B of epoxy groups of the epoxy resin that react with the epoxy group of the curing agent contained in the epoxy resin composition
- the ratio of (A / B) is preferably 0.3 to 3.0, and more preferably 0.5 to 2.0.
- the epoxy resin composition may optionally contain other components other than the epoxy resin and the curing agent.
- a curing catalyst, a filler, etc. may be included.
- Specific examples of the curing catalyst include compounds exemplified as reaction catalysts which can be used for synthesis of multimers.
- the molded article of the present disclosure contains the epoxy resin cured product of the present disclosure.
- the application of the molded body is not particularly limited.
- the epoxy resin cured product of the present disclosure can maintain good light transmittance by not forming a smectic structure, it can also be suitably used in the field of optical parts and the like where transparency is required.
- the composite material of the present disclosure includes the epoxy resin cured product of the present disclosure and a reinforcing material.
- the material of the reinforcing material contained in the composite material is not particularly limited, and can be selected according to the application of the composite material.
- Specific examples of the reinforcing material include glass, aromatic polyamide resins (eg, Kevlar (registered trademark)), ultrahigh molecular weight polyethylene, alumina, boron nitride, aluminum nitride, mica, silicon and the like.
- the shape of the reinforcing material is not particularly limited, and examples thereof include fibrous and particulate (filler).
- the reinforcing material contained in the composite material may be one kind alone or two or more kinds.
- the form of the composite material is not particularly limited.
- it may have at least one cured product-containing layer containing a cured epoxy resin and at least one reinforcing material-containing layer containing a reinforcing material.
- the cured product-containing layer may contain a reinforcing material
- the reinforcing material-containing layer may contain a cured epoxy resin product.
- the epoxy resin B contained the reaction product of the epoxy compound A and the specific aromatic compound A, the unreacted epoxy compound A, and a part of the synthesis solvent.
- the epoxy resin C was synthesized under the same conditions as the synthesis of the epoxy resin B except that the addition amount of the specific aromatic compound A (hydroquinone) was changed from 1.6 parts by mass to 3.1 parts by mass.
- the epoxy resin C contained the reaction product of the epoxy compound A and the specific aromatic compound A, the unreacted epoxy compound A, and a part of the synthesis solvent.
- Epoxy resin B 100.0 parts by mass (nonvolatile matter), poly (1,4-butanediol) bis (4-aminobenzoic acid) as a curing agent (number average molecular weight 470, SIGMA-ALDRICH): 43.5 A mass part was added to obtain a resin composition.
- the resin composition was placed in a stainless steel petri dish and heated to 180 ° C. on a hot plate. After the resin composition in the stainless steel petri dish was melted, it was heated at 150 ° C. for 2 hours. After cooling to normal temperature (25 ° C.), a sample was taken out from the stainless steel petri dish, and heated at 230 ° C. in an oven for 1 hour to obtain a cured epoxy resin product.
- the resulting epoxy resin cured product was polished to a thickness of 3.75 mm to prepare a test piece for evaluating the total light transmittance. Further, the cured epoxy resin was cut into a rectangular parallelepiped of 3.75 mm ⁇ 7.5 mm ⁇ 33 mm to prepare a test piece for evaluation of fracture toughness. Furthermore, the epoxy resin cured product was cut into strips of 2 mm ⁇ 0.5 mm ⁇ 40 mm, and test pieces for evaluation of glass transition temperature were produced.
- Epoxy compound A 50.0 parts by mass of poly (1,4-butanediol) bis (4-aminobenzoic acid) as a specific curing agent is added to 100.0 parts by mass (nonvolatile content) of the epoxy resin composition. Obtained.
- the epoxy resin composition was placed in a stainless steel petri dish and heated to 200 ° C. with a hot plate. After the epoxy resin composition in the stainless steel petri dish melted, it was heated at 200 ° C. for 1 hour. After cooling to normal temperature (25 ° C.), a sample was taken out from the stainless steel petri dish, and heated at 230 ° C. in an oven for 1 hour to obtain a cured epoxy resin product. Test pieces were produced in the same manner as in Example 1 from the obtained cured epoxy resin product.
- Example 3 In the same manner as in Example 2 using 100.0 parts by mass (nonvolatile content) of epoxy resin B and 43.5 parts by mass of poly (1,4-butanediol) bis (4-aminobenzoic acid) An epoxy resin cured product and a test piece were obtained.
- Example 4 In the same manner as in Example 2 using 100.0 parts by mass (nonvolatiles) of epoxy resin C and 35.2 parts by mass of poly (1,4-butanediol) bis (4-aminobenzoic acid) An epoxy resin cured product and a test piece were obtained.
- Example 5 In the same manner as in Example 2 using 100.0 parts by mass (nonvolatile content) of epoxy resin D and 35.6 parts by mass of poly (1,4-butanediol) bis (4-aminobenzoic acid) An epoxy resin cured product and a test piece were obtained.
- Comparative Example 2 100 parts by mass (nonvolatiles) of bisphenol A epoxy resin (YL 980, Mitsubishi Chemical Co., Ltd.) and 26.6 parts by mass of diaminodiphenylmethane (Wako Pure Chemical Industries, Ltd.): the temperature of the hot plate is 150
- the epoxy resin cured product and the test piece were obtained in the same manner as Example 2, changing to ° C.
- Comparative Example 4 An RS Pro acrylic sheet (ASS Components Co., Ltd.) was polished to a thickness of 3.75 mm to prepare a test piece for evaluating the total light transmittance. Moreover, the said acrylic sheet was cut out in the rectangular parallelepiped of 3.75 mm x 7.5 mm x 33 mm, and the test piece for evaluation of fracture toughness was produced. Furthermore, the said acrylic sheet was cut out in 2 mm * 0.5 mm * 40 mm strip shape, and the test piece for evaluation of glass transition temperature was produced.
- Glass-transition temperature About the test piece for evaluation of the glass transition temperature produced by the Example and the comparative example, the dynamic viscoelasticity measurement by tension mode was performed, and the glass transition temperature (degreeC) was computed.
- the measurement conditions were: frequency: 10 Hz, temperature rising rate: 5 ° C./min, strain: 0.1%.
- the peak of the obtained tan ⁇ chart was regarded as the glass transition temperature.
- a dynamic viscoelasticity measurement device (RSA-G2, TA Instruments Co., Ltd.) was used as the glass transition temperature.
- RSA-G2 TA Instruments Co., Ltd.
- Total light transmittance About the test piece for evaluation of the total light transmittance produced by the Example and the comparative example, the total light transmittance (%) was measured. The measurement conditions were a film thickness of 3.75 mm. A haze meter (NDH-5000, Nippon Denshoku Kogyo Co., Ltd.) was used as an evaluation device. The results are shown in Table 1. When the smectic structure was formed, the measurement was not performed because the total light transmittance was extremely low.
- the cured epoxy resin product of Example 1 prepared using the epoxy compound having a mesogen structure and the specific cured product is prepared using an epoxy compound having a mesogenic structure and a curing agent different from the specific cured product.
- the fracture toughness value was significantly improved.
- the glass transition temperature was lowered, a practically sufficient level was maintained.
- the epoxy resin cured product of Comparative Example 3 produced using an epoxy compound having no mesogen structure and a specific cured product is a comparative example 2 produced using an epoxy compound having no mesogen structure and a curing agent different from the specific cured product.
- the fracture toughness value was improved compared to the epoxy resin cured product, the glass transition temperature was significantly reduced.
- Example 2 to 5 in which the heating temperature on the hot plate was set to 200 ° C., no smectic structure was formed in the epoxy resin cured product, and an epoxy resin cured product having a total light transmittance of more than 60% was obtained.
- Comparative Example 4 using an acrylic sheet had a high total light transmittance of 89% and a low fracture toughness value and a low glass transition temperature, as compared with the example using a cured epoxy resin.
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Abstract
Description
<1>メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖又は柔軟性骨格を有する硬化剤との硬化物であり、スメクチック構造を有するエポキシ樹脂硬化物。
<2>メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖又は柔軟性骨格を有する硬化剤との硬化物であり、スメクチック構造を有しないエポキシ樹脂硬化物。
<3>メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖を有する硬化剤と、を含むエポキシ樹脂組成物。
<4>メソゲン構造を有するエポキシ化合物と、分子中に柔軟性骨格を有する硬化剤と、を含むエポキシ樹脂組成物。
<5>前記硬化剤は少なくとも2つの官能基を有し、そのうち一方の官能基ともう一方の官能基との間に前記分子鎖又は前記柔軟性骨格が配置されている、<1>若しくは<2>に記載のエポキシ樹脂硬化物又は<3>若しくは<4>に記載のエポキシ樹脂組成物。
<6>前記分子鎖又は前記柔軟性骨格がアルキレン基、アルキレンオキシ基及びシロキサン結合からなる群より選択される少なくとも1種を含む、<1>若しくは<2>に記載のエポキシ樹脂硬化物又は<3>~<5>のいずれか1項に記載のエポキシ樹脂組成物。
<7>前記硬化剤がアミン硬化剤を含む、<1>若しくは<2>に記載のエポキシ樹脂硬化物又は<3>~<6>のいずれか1項に記載のエポキシ樹脂組成物。
<8>前記硬化剤が芳香族アミン化合物を含む、<1>若しくは<2>に記載のエポキシ樹脂硬化物又は<3>~<7>のいずれか1項に記載のエポキシ樹脂組成物。
<9>硬化させた際の破壊靭性値が1.8MPa・m1/2を超える、<3>~<8>のいずれか1項に記載のエポキシ樹脂組成物。
<10>硬化させた際のガラス転移温度が120℃を超える、<3>~<9>のいずれか1項に記載のエポキシ樹脂組成物。
<11>硬化させた際の全光線透過率が60%を超える、<3>~<10>のいずれか1項に記載のエポキシ樹脂組成物。
<12><3>~<11>のいずれか1項に記載のエポキシ樹脂組成物の硬化物である、エポキシ樹脂硬化物。
<13><1>、<2>又は<12>に記載のエポキシ樹脂硬化物を含む成形体。
<14><1>、<2>又は<12>に記載のエポキシ樹脂硬化物と、強化材と、を含む複合材料。
<15>前記エポキシ樹脂硬化物を含む少なくとも1つの硬化物含有層と、前記強化材を含む少なくとも1つの強化材含有層とを有する、<14>に記載の複合材料。
本開示において「~」を用いて示された数値範囲には、「~」の前後に記載される数値がそれぞれ最小値及び最大値として含まれる。
本開示中に段階的に記載されている数値範囲において、一つの数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本開示中に記載されている数値範囲において、その数値範囲の上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本開示において各成分は該当する物質を複数種含んでいてもよい。組成物中に各成分に該当する物質が複数種存在する場合、各成分の含有率又は含有量は、特に断らない限り、組成物中に存在する当該複数種の物質の合計の含有率又は含有量を意味する。
本開示において各成分に該当する粒子は複数種含んでいてもよい。組成物中に各成分に該当する粒子が複数種存在する場合、各成分の粒子径は、特に断らない限り、組成物中に存在する当該複数種の粒子の混合物についての値を意味する。
本開示において「層」との語には、当該層が存在する領域を観察したときに、当該領域の全体に形成されている場合に加え、当該領域の一部にのみ形成されている場合も含まれる。
本開示において「エポキシ化合物」とは、分子中にエポキシ基を有する化合物を意味する。「エポキシ樹脂」とは、複数のエポキシ化合物を集合体として捉える概念であって硬化していない状態のものを意味する。
本開示のエポキシ樹脂硬化物(第1実施形態)は、メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖又は柔軟性骨格を有する硬化剤(以下、特定硬化剤とも称する)との硬化物であり、スメクチック構造を有する。
あるいは、偏光顕微鏡による干渉像の観察によってスメクチック構造の有無を確認することもできる。
エポキシ樹脂硬化物中にスメクチック構造を形成するか形成しないかを硬化条件により決定する場合の手法としては、硬化温度が高いとスメクチック構造が形成されにくく、硬化温度が低いとスメクチック構造が形成されやすい性質を利用して硬化温度を制御することが挙げられる。ただし本開示はこの手法に制限されない。
エポキシ樹脂硬化物の破壊靱性値(MPa・m1/2)は特に制限されず、エポキシ樹脂硬化物の用途等に応じて設定できる。例えば、1.8MPa・m1/2を超えることが好ましく、1.9MPa・m1/2以上であることがより好ましく、2.0MPa・m1/2以上であることがさらに好ましい。破壊靱性値の上限は特に制限されないが、ガラス転移温度(耐熱性)との兼ね合いの観点からは4.0MPa・m1/2以下であることが好ましく、3.7MPa・m1/2以下であることがより好ましく、3.5MPa・m1/2以下であることがさらに好ましい。
エポキシ樹脂硬化物の全光線透過率(%)は特に制限されず、エポキシ樹脂硬化物の用途等に応じて設定できる。例えば、60%を超えることが好ましく、65%以上であることがより好ましく、70%以上であることがさらに好ましい。全光線透過率の上限は特に制限されないが、他の特性との兼ね合いからは95%以下であることが好ましく、93%以下であることがより好ましく、90%以下であることがさらに好ましい。
エポキシ樹脂硬化物のガラス転移温度(℃)は特に制限されず、エポキシ樹脂硬化物の用途等に応じて設定できる。耐熱性の観点からは、120℃を超えることが好ましく、125℃以上であることがより好ましく、130℃以上であることがさらに好ましい。良好な破壊靭性を確保する観点からは、350℃以下であることが好ましく、300℃以下であることがより好ましく、250℃以下であることがさらに好ましい。
本開示のエポキシ樹脂組成物(第1実施形態)は、メソゲン構造を有するエポキシ化合物と、特定硬化剤と、を含む。
エポキシ樹脂組成物に含まれるメソゲン構造を有するエポキシ化合物は、1種でも2種以上であってもよい。
あるいは、例えば、エポキシモノマーと、エポキシ基と反応しうる官能基を有する化合物と、必要に応じて用いる反応触媒とを、溶媒を用いずに混合し、加熱しながら撹拌することで行うことができる。
ジアミノベンゼン化合物としては、1,2-ジアミノベンゼン、1,3-ジアミノベンゼン、1,4-ジアミノベンゼン、これらの誘導体等が挙げられる。
特定芳香族化合物の誘導体としては、特定芳香族化合物のベンゼン環に炭素数1~8のアルキル基等の置換基が結合した化合物が挙げられる。特定芳香族化合物は、1種を単独で用いてもよく、2種以上を併用してもよい。
有機リン化合物の好ましい例としては、有機ホスフィン化合物、有機ホスフィン化合物に無水マレイン酸、キノン化合物、ジアゾフェニルメタン、フェノール樹脂等のπ結合をもつ化合物を付加してなる分子内分極を有する化合物、有機ホスフィン化合物と有機ボロン化合物との錯体などが挙げられる。
まず、エポキシモノマーを反応容器に投入し、必要に応じて溶媒を入れ、オイルバス又は熱媒により反応温度まで加温し、エポキシモノマーを溶解する。そこにエポキシ基と反応しうる官能基を有する化合物を投入し、次いで必要に応じて反応触媒を投入し、反応を開始させる。次いで、必要に応じて減圧下で溶媒を留去することで、多量体を含む反応物が得られる。
特定硬化剤は、エポキシ樹脂組成物に含まれるエポキシ樹脂と硬化反応を生じることができる化合物であれば、特に制限されない。例えば、アミン硬化剤、フェノール硬化剤、酸無水物硬化剤、ポリメルカプタン硬化剤、ポリアミノアミド硬化剤、イソシアネート硬化剤、ブロックイソシアネート硬化剤等が挙げられる。特定硬化剤は、1種を単独で用いても2種以上を併用してもよい。
エポキシ樹脂組成物が特定硬化剤以外の硬化剤を含む場合、その種類は特に制限されない。例えば、特定硬化剤以外のアミン硬化剤として具体的には、3,3’-ジアミノジフェニルスルホン、4,4’-ジアミノジフェニルスルホン、4,4’-ジアミノジフェニルメタン、4,4’-ジアミノジフェニルエーテル、4,4’-ジアミノ-3,3’-ジメトキシビフェニル、4,4’-ジアミノフェニルベンゾエート、1,5-ジアミノナフタレン、1,3-ジアミノナフタレン、1,4-ジアミノナフタレン、1,8-ジアミノナフタレン、1,3-ジアミノベンゼン、1,4-ジアミノベンゼン、4,4’-ジアミノベンズアニリド、トリメチレン-ビス-4-アミノベンゾアート等が挙げられる。
エポキシ樹脂組成物は、必要に応じてエポキシ樹脂と硬化剤以外のその他の成分を含んでもよい。例えば、硬化触媒、フィラー等を含んでもよい。硬化触媒の具体例としては、多量体の合成に使用しうる反応触媒として例示した化合物が挙げられる。
本開示の成形体は、本開示のエポキシ樹脂硬化物を含む。
成形体の用途は特に制限されない。例えば、本開示のエポキシ樹脂硬化物は、スメクチック構造を形成しないことにより良好な光透過性を維持できるため、透明性が要求される光学部品等の分野にも好適に使用することができる。
本開示の複合材料は、本開示のエポキシ樹脂硬化物と、強化材と、を含む。
複合材料に含まれる強化材の材質は特に制限されず、複合材料の用途等に応じて選択できる。強化材として具体的には、ガラス、芳香族ポリアミド系樹脂(例えば、ケブラー(登録商標))、超高分子量ポリエチレン、アルミナ、窒化ホウ素、窒化アルミニウム、マイカ、シリコン等が挙げられる。強化材の形状は特に制限されず、繊維状、粒子状(フィラー)等が挙げられる。複合材料に含まれる強化材は、1種のみでも2種以上であってもよい。
500mLの三口フラスコに、下記構造で示されるエポキシ化合物A(特許第5471975号公報参照):50質量部を量り取り、そこに合成溶媒(シクロヘキサノン):80質量部を添加した。三口フラスコに冷却管及び窒素導入管を設置し、合成溶媒に漬かるように撹拌羽を取り付けた。この三口フラスコを160℃のオイルバスに浸漬し、撹拌を開始した。数分後にエポキシ化合物が溶解し、透明な溶液になったことを確認した後に、特定芳香族化合物A(ヒドロキノン):1.6質量部をフラスコに添加し、さらに反応触媒(トリフェニルホスフィン):0.5質量部を添加し、160℃のオイルバス温度で加熱を継続した。5時間加熱を継続した後に、反応溶液からシクロヘキサノンを減圧留去し、残渣を室温(25℃)まで冷却して、エポキシ樹脂Bを得た。エポキシ樹脂Bには、エポキシ化合物Aと特定芳香族化合物Aとの反応物と、未反応のエポキシ化合物Aと、合成溶媒の一部とが含まれていた。
特定芳香族化合物A(ヒドロキノン)の添加量を1.6質量部から3.1質量部に変更した以外はエポキシ樹脂Bの合成と同様の条件で、エポキシ樹脂Cを合成した。エポキシ樹脂Cには、エポキシ化合物Aと特定芳香族化合物Aの反応物と、未反応のエポキシ化合物Aと、合成溶媒の一部とが含まれていた。
特定芳香族化合物A(ヒドロキノン)を別の特定芳香族化合物B(ビフェノール)に変更し、添加量を1.6質量部から4.3質量部に変更した以外はエポキシ樹脂Bの合成と同様の条件で、エポキシ樹脂Dを合成した。エポキシ樹脂Dにはエポキシ化合物Aと特定芳香族化合物Bの反応物と、未反応のエポキシ化合物Aと、合成溶媒の一部とが含まれていた。
エポキシ樹脂B:100.0質量部(不揮発分)に、硬化剤としてポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸)(数平均分子量470、SIGMA-ALDRICH社):43.5質量部を加えて樹脂組成物を得た。樹脂組成物をステンレスシャーレに入れ、ホットプレートで180℃に加熱した。ステンレスシャーレ内の樹脂組成物が溶融した後に、150℃で2時間加熱した。常温(25℃)に冷却した後にステンレスシャーレから試料を取り出し、オーブンにて230℃で1時間加熱してエポキシ樹脂硬化物を得た。
エポキシ化合物A:100.0質量部(不揮発分)に、特定硬化剤としてポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸):52.5質量部を加えてエポキシ樹脂組成物を得た。このエポキシ樹脂組成物をステンレスシャーレに入れ、ホットプレートで200℃に加熱した。ステンレスシャーレ内のエポキシ樹脂組成物が溶融した後に、200℃で1時間加熱した。常温(25℃)に冷却した後にステンレスシャーレから試料を取り出し、オーブンにて230℃で1時間加熱してエポキシ樹脂硬化物を得た。得られたエポキシ樹脂硬化物から実施例1と同様にして試験片を作製した。
エポキシ樹脂B:100.0質量部(不揮発分)と、ポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸):43.5質量部とを使用し、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
エポキシ樹脂C:100.0質量部(不揮発分)と、ポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸):35.2質量部とを使用し、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
エポキシ樹脂D:100.0質量部(不揮発分)と、ポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸):35.6質量部とを使用し、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
エポキシ樹脂B:100.0質量部(不揮発分)と、ジアミノジフェニルメタン(和光純薬工業株式会社):18.4質量部とを使用し、ホットプレートの温度を150℃へと変更して、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
ビスフェノールA型エポキシ樹脂(YL980、三菱ケミカル株式会社):100質量部(不揮発分)と、ジアミノジフェニルメタン(和光純薬工業株式会社):26.6質量部とを使用し、ホットプレートの温度を150℃へと変更して、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
ビスフェノールA型エポキシ樹脂(YL980、三菱ケミカル株式会社):100質量部(不揮発分)と、ポリ(1,4-ブタンジオール)ビス(4-アミノ安息香酸):63.2質量部とを使用し、実施例2と同様にしてエポキシ樹脂硬化物及び試験片を得た。
RS Pro アクリルシート(アールエスコンポーネンツ株式会社)を、厚さ3.75mmにまで研磨し、全光線透過率評価用の試験片を作製した。また、前記アクリルシートを3.75mm×7.5mm×33mmの直方体に切り出し、破壊靱性の評価用の試験片を作製した。さらに、前記アクリルシートを2mm×0.5mm×40mmの短冊状に切り出し、ガラス転移温度の評価用の試験片を作製した。
実施例及び比較例で作製した破壊靱性値の評価用の試験片について、ASTM D5045に基づいて3点曲げ測定を行って破壊靱性値(MPa・m1/2)を算出した。評価装置としては、曲げ試験機(インストロン5948、インストロン社)を用いた。結果を表1に示す。
実施例及び比較例で作製したガラス転移温度の評価用の試験片について、引張りモードによる動的粘弾性測定を行ってガラス転移温度(℃)を算出した。測定条件は、振動数:10Hz、昇温速度:5℃/min、歪み:0.1%とした。得られたtanδチャートのピークをガラス転移温度とみなした。評価装置としては、動的粘弾性測定装置(RSA-G2、ティー・エイ・インスツルメント社)を用いた。結果を表1に示す。
実施例及び比較例で作製した全光線透過率の評価用の試験片について、全光線透過率(%)を測定した。測定条件は、膜厚3.75mmとした。評価装置としては、ヘーズメーター(NDH-5000、日本電色工業株式会社)を用いた。結果を表1に示す。なお、スメクチック構造が形成されている場合は全光線透過率が著しく低いため、測定を行わなかった。
エポキシ樹脂硬化物中にスメクチック構造が形成されているか否かは、上述した条件でX線回折測定を行ったときの回折ピークの有無によって判断した。結果を表1に示す。
アクリルシートを用いた比較例4は、エポキシ樹脂硬化物を用いた実施例に比べて全光線透過率が89%と高いものの破壊靱性値とガラス転移温度が低かった。
Claims (15)
- メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖又は柔軟性骨格を有する硬化剤との硬化物であり、スメクチック構造を有するエポキシ樹脂硬化物。
- メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖又は柔軟性骨格を有する硬化剤との硬化物であり、スメクチック構造を有しないエポキシ樹脂硬化物。
- メソゲン構造を有するエポキシ化合物と、分子量が100以上の分子鎖を有する硬化剤と、を含むエポキシ樹脂組成物。
- メソゲン構造を有するエポキシ化合物と、分子中に柔軟性骨格を有する硬化剤と、を含むエポキシ樹脂組成物。
- 前記硬化剤は少なくとも2つの官能基を有し、そのうち一方の官能基ともう一方の官能基との間に前記分子鎖又は前記柔軟性骨格が配置されている、請求項1若しくは請求項2に記載のエポキシ樹脂硬化物又は請求項3若しくは請求項4に記載のエポキシ樹脂組成物。
- 前記分子鎖又は前記柔軟性骨格がアルキレン基、アルキレンオキシ基及びシロキサン結合からなる群より選択される少なくとも1種を含む、請求項1若しくは請求項2に記載のエポキシ樹脂硬化物又は請求項3~請求項5のいずれか1項に記載のエポキシ樹脂組成物。
- 前記硬化剤がアミン硬化剤を含む、請求項1若しくは請求項2に記載のエポキシ樹脂硬化物又は請求項3~請求項6のいずれか1項に記載のエポキシ樹脂組成物。
- 前記硬化剤が芳香族アミン化合物を含む、請求項1若しくは請求項2に記載のエポキシ樹脂硬化物又は請求項3~請求項7のいずれか1項に記載のエポキシ樹脂組成物。
- 硬化させた際の破壊靭性値が1.8MPa・m1/2を超える、請求項3~請求項8のいずれか1項に記載のエポキシ樹脂組成物。
- 硬化させた際のガラス転移温度が120℃を超える、請求項3~請求項9のいずれか1項に記載のエポキシ樹脂組成物。
- 硬化させた際の全光線透過率が60%を超える、請求項3~請求項10のいずれか1項に記載のエポキシ樹脂組成物。
- 請求項3~請求項11のいずれか1項に記載のエポキシ樹脂組成物の硬化物である、エポキシ樹脂硬化物。
- 請求項1、請求項2又は請求項12に記載のエポキシ樹脂硬化物を含む成形体。
- 請求項1、請求項2又は請求項12に記載のエポキシ樹脂硬化物と、強化材と、を含む複合材料。
- 前記エポキシ樹脂硬化物を含む少なくとも1つの硬化物含有層と、前記強化材を含む少なくとも1つの強化材含有層とを有する、請求項14に記載の複合材料。
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| PCT/JP2017/031209 WO2019043843A1 (ja) | 2017-08-30 | 2017-08-30 | エポキシ樹脂硬化物、エポキシ樹脂組成物、成形体及び複合材料 |
| CN201780094404.3A CN111032721A (zh) | 2017-08-30 | 2017-08-30 | 环氧树脂固化物、环氧树脂组合物、成形体及复合材料 |
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| US20210054133A1 (en) | 2021-02-25 |
| CN111032721A (zh) | 2020-04-17 |
| KR20200041898A (ko) | 2020-04-22 |
| KR102379662B1 (ko) | 2022-03-25 |
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