In-situ polymerized type thermoplastic prepreg, thermoplastic composite, and methods of manufacturing the same
An in-situ polymerized type thermoplastic prepreg is provided, which is excellent in productivity, has tack properties and drape properties that allow easy shaping in a mold, is excellent in handling properties, and allows a molded product obtained by curing to have both mechanical properties as high as those of a thermosetting composite and the features of the thermoplastic composite. An in-situ polymerized type thermoplastic prepreg 1 includes reinforcing fibers 2 and an in-situ polymerized type thermoplastic epoxy resin 3 as a matrix resin. The in-situ polymerized type thermoplastic epoxy resin 3 is cured to B-stage, with the weight-average molecular weight being 6,000 or less, and has tack properties and drape properties at 30° C. or less, and the in-situ polymerized type thermoplastic epoxy resin after curing has a weight-average molecular weight of 30,000 or more.
1. An in-situ polymerized type thermoplastic prepreg comprising reinforcing fibers and an in-situ polymerized type thermoplastic epoxy resin as a matrix resin,
wherein the in-situ polymerized type thermoplastic epoxy resin is semi-cured to partial polymerization, with a viscosity of 100 Pa·s to 1,000 Pa·s at 25° C. and a weight-average molecular weight being not more than 6,000, and has tack properties and drape properties at not more than 30° C., and
wherein the in-situ polymerized type thermoplastic epoxy resin after complete polymerization has a weight-average molecular weight of not less than 30,000 and exhibits thermoplasticity.
2. The in-situ polymerized type thermoplastic prepreg according to claim 1 , wherein the uncured in-situ polymerized type thermoplastic epoxy resin comprises
(a) a first bifunctional compound having two epoxy groups, and
(b) a second bifunctional compound having two functional groups of at least one type selected from the group consisting of a phenolic hydroxyl group, an amino group, a carboxyl group, a mercapto group, an isocyanate group, and a cyanate ester group.
3. The in-situ polymerized type thermoplastic prepreg according to claim 1 , wherein the in-situ polymerized type thermoplastic prepreg has a resin content ratio of 20 wt % to 40 wt %.
4. The in-situ polymerized type thermoplastic prepreg according to claim 1 , wherein the reinforcing fibers have a weight per unit area of 50 g/m 2 to 500 g/m 2 .
5. The in-situ polymerized type thermoplastic prepreg according to claim 1 , wherein the reinforcing fibers have a tensile modulus of more than 40 GPa and are unidirectional continuous fibers paralleled in one direction.