Structural material and process for its production

• US 6,335,100 B1
• Filed: 09/28/1992
• Issued: 01/01/2002
• Est. Priority Date: 05/31/1985
• Status: Expired due to Fees

• Current Assignee: SRI Sports Limited (Sumitomo Rubber Industries Limited)
• Original Assignee: Sumitomo Rubber Industries Limited
• Inventors: Niwa, Kunio, Tominaga, Ichiro, Matsushita, Hiroomi, Matsuki, Taketo, Yamaguchi, Tetsuo
• Primary Examiner(s): WEISBERGER, RICHARD C
• Application Number:
  US07/952,137
• Time in Patent Office: 3,382 Days
• Field of Search: 428/224, 428/288, 428/474.4, 156/275.5
• US Class Current: 428/474.4
• CPC Class Codes: C08J 2377/02 Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08J2377/10 takes precedence
• CPC Class Codes: C08J 5/04 Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/31725 Of polyamide

Abstract

Disclosed is a structural material excelling in lightness of weight, strength, flexural modulus and other properties, being made from polyamide resin reinforced with continuous fiber and/or long filament reinforcing material. This structural material can be fabricated by a monomer casting method by arranging said fiber reinforcing material preliminarily in a desired shape, putting it into a mold, pouring molten ω-lactams containing a polymerization catalyst and an initiator into said mold, and heating to obtain polyamide resin.

Claims

1. A molded article consisting of a polyamide resin reinforced by a reinforcing material which is one selected from the group consisting of continuous fiber and filament having a length of at least 1 mm, said molded article being obtained by a monomer casting method comprising the steps of:

(1) treating said reinforcing material with an agent for improving the adhesion between said reinforcing material and said polyamide resin, wherein said agent is soluble in alcohol or water or in both alcohol and water;

(2) arranging said treated reinforcing material in a desired shape;

(3) placing the thus arranged reinforcing material in a mold;

(4) pouring a molten ω

-lactam composition containing a polymerization catalyst and an initiator into said mold; and

(5) heating the molten ω

-lactam composition to obtain a polyamide resin, thereby forming said molded article.

2. A molded article according to claim 1, wherein the intrinsic viscosity (η

) of said polyamide resin is at least 1.8.

3. A molded article according to claim 2, wherein said polyamide resin contains 10 to 80% by weight of reinforcing material.

4. A molded article according to claim 3, wherein said reinforcing material is at least one member selected from the group consisting of carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, steel wire and amorphous metal fiber.

5. A molded article according to claim 1, wherein said polyamide resin contains 10 to 80% by weight of reinforcing material.

6. A molded article according to claim 5, wherein said reinforcing material is at least one member selected from the group consisting of carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, steel wire and amorphous metal fiber.

7. A molded article according to claim 1, wherein said molded article is a bar.

8. A molded article according to claim 7, wherein the intrinsic viscosity (η

) of said polyamide resin is at least 1.8.

9. A molded article according to claim 8, wherein said polyamide resin contains 10 to 80% by weight of reinforcing material.

10. A molded article according to claim 9, wherein said reinforcing material is at least one member selected from the group consisting of carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, steel wire and amorphous metal fiber.

11. A molded article according to claim 1, wherein said molded article is a tennis racket.

12. A molded article according to claim 11, wherein the intrinsic viscosity (η

) of said polyamide resin is at least 1.8.

13. A molded article according to claim 12, wherein said polyamide resin contains 10 to 80% by weight of reinforcing material.

14. A molded article according to claim 13, wherein said reinforcing material is at least one member selected from the group consisting of carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, steel wire and amorphous metal fiber.

15. A molded article according to claim 1, wherein said reinforcing material is at least one member selected from the group consisting of carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, steel wire and amorphous metal fiber.

16. A molded article according to claim 1, wherein said reinforcing material is a braided material.

17. A molded article according to claim 1, wherein said reinforcing material is a cloth.

18. A molded article according to claim 1, wherein said reinforcing material is a sleeve.

19. A molded article according to claim 1, wherein said reinforcing material is a roving.

20. A molded article according to claim 1, wherein said reinforcing material is wound around a mandrel which is placed in said mold.