Epoxy resin composition for fiber-reinforced composite material, method for producing epoxy resin composition for fiber-reinforced composite material, prepreg, and honey-comb panel

Patent metadata

Field	Value
Publication number	US-10174200-B2
Application number	US-201515512509-A
Country	US
Kind code	B2
Filing date	Jun 9, 2015
Priority date	Sep 19, 2014
Publication date	Jan 8, 2019
Grant date	Jan 8, 2019

Abstract

The present technology provides an epoxy resin composition for a fiber-reinforced composite material, a method for producing an epoxy resin composition for a fiber-reinforced composite material, a prepreg, and a honeycomb panel. The epoxy resin composition for a fiber-reinforced composite material of the present technology contains: a reaction product obtained by reacting 100 parts by mass of a phosphorus-containing epoxy resin containing a phosphorus atom in the backbone thereof, and not less than 5 parts by mass and not greater than 20 parts by mass of an amino-terminated butadiene-acrylonitrile rubber; an epoxy resin other than the phosphorus-containing epoxy resin; a curing agent; and a curing accelerator.

First claim

The invention claimed is:

1. An epoxy resin composition for a fiber-reinforced composite material comprising:
a reaction product obtained by reacting 100 parts by mass of a phosphorus-containing epoxy resin containing a phosphorus atom in a backbone thereof, and not less than 5 parts by mass and not greater than 20 parts by mass of an amino-terminated liquid rubber;
an epoxy resin different than the phosphorus-containing epoxy resin;
a curing agent; and
a curing accelerator; wherein:
a compounded amount of the phosphorus-containing epoxy resin is not less than 50 parts by mass and not greater than 95 parts by mass per 100 parts by mass of a total amount of the phosphorus-containing epoxy resin and the epoxy resin different than the phosphorus-containing epoxy resin;
a compounded amount of the phosphorus-containing epoxy resin is not less than 30 mass % and not greater than 80 mass % with respect to the total mass of the epoxy resin composition; and
the phosphorus-containing epoxy resin has lower reactivity than that of the epoxy resin different than the phosphorus-containing epoxy resin, and the reaction product has crosslinking as a result of the reaction between the phosphorus-containing epoxy resin and the amino-terminated liquid rubber.

2. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , wherein the amino-terminated liquid rubber is an amino-terminated butadiene-acrylonitrile rubber.

3. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , wherein the curing accelerator contains at least one type selected from the group consisting of phenylurea-based compounds represented by Formula (1):

where R 1 is a phenyl group and R 2 and R 3 are alkyl groups.

4. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , wherein the curing agent is dicyandiamide.

5. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , wherein a phosphorus content of the phosphorus-containing epoxy resin is not less than 0.5 mass % and not greater than 5.0 mass %.

6. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , wherein a content of the curing accelerator is not less than 1 part by mass and not greater than 15 parts by mass per 100 parts by mass of a sum of a mass of the phosphorus-containing epoxy resin and a mass of the other epoxy resin.

7. The epoxy resin composition for a fiber-reinforced composite material according to claim 1 , further comprising a phenoxy resin.

8. The epoxy resin composition for a fiber-reinforced composite material according to claim 7 , wherein a content of the phenoxy resin is not less than 5 parts by mass and not greater than 40 parts by mass per 100 parts by mass of a sum of a mass of the phosphorus-containing epoxy resin and a mass of the other epoxy resin.

9. A method for producing an epoxy resin composition for a fiber-reinforced composite material, the method comprising:
reacting 100 parts by mass of a phosphorus-containing epoxy resin containing a phosphorus atom in a backbone thereof and not less than 5 parts by mass and not greater than 20 parts by mass of an amino-terminated liquid rubber for not less than 10 minutes and not greater than 3 hours at a reaction temperature of not lower than 100° C. and not higher than 200° C. to obtain a reaction product; and
mixing the reaction product, an epoxy resin different than the phosphorus-containing epoxy resin, a curing agent, and a curing accelerator to obtain an epoxy resin composition for a fiber-reinforced composite material wherein a compounded amount of the phosphorus-containing epoxy resin is not less than 50 parts by mass and not greater than 95 parts by mass per 100 parts by mass of a total amount of the phosphorus-containing epoxy resin and the epoxy resin different than the phosphorus-containing epoxy resin; a compounded amount of the phosphorus-containing epoxy resin is not less than 30 mass % and not greater than 80 mass % with respect to the total mass of the epoxy resin composition; and the phosphorus-containing epoxy resin has lower reactivity than that of the epoxy resin different than the phosphorus-containing epoxy resin, and the reaction product has crosslinking as a result of the reaction between the phosphorus-containing epoxy resin and the amino-terminated liquid rubber.

10. A prepreg obtained by impregnating a reinforced fiber with the epoxy resin composition for a fiber-reinforced composite material according to claim 1 .

11. A honeycomb panel obtained by laminating and curing the prepreg according to claim 10 and a honeycomb core.

12. The honeycomb panel according to claim 11 , wherein the honeycomb core is at least one type selected from the group consisting of an aramid honeycomb, an aluminum honeycomb, a paper honeycomb, and a glass honeycomb.

13. The epoxy resin composition for a fiber-reinforced composite material according to claim 2 , wherein the curing accelerator contains at least one type selected from the group consisting of phenylurea-based compounds represented by Formula (1):

where R 1 is a phenyl group and R 2 and R 3 are alkyl groups.

14. The epoxy resin composition for a fiber-reinforced composite material according to claim 13 , wherein the curing agent is dicyandiamide.

15. The epoxy resin composition for a fiber-reinforced composite material according to claim 14 , wherein a phosphorus content of the phosphorus-containing epoxy resin is not less than 0.5 mass % and not greater than 5.0 mass %.

16. The epoxy resin composition for a fiber-reinforced composite material according to claim 15 , wherein a content of the curing accelerator is not less than 1 part by mass and not greater than 15 parts by mass per 100 parts by mass of a sum of a mass of the phosphorus-containing epoxy resin and a mass of the other epoxy resin.

17. The epoxy resin composition for a fiber-reinforced composite material according to claim 16 , further comprising a phenoxy resin.

18. The epoxy resin composition for a fiber-reinforced composite material according to claim 17 , wherein a content of the phenoxy resin is not less than 5 parts by mass and not greater than 40 parts by mass per 100 parts by mass of a sum of a mass of the phosphorus-containing epoxy resin and a mass of the other epoxy resin.

19. A prepreg obtained by impregnating a reinforced fiber with the epoxy resin composition for a fiber-reinforced composite material according to claim 18 .

20. A honeycomb panel obtained by laminating and curing the prepreg according to claim 19 and a honeycomb core, wherein the honeycomb core is at least one type selected from the group consisting of an aramid honeycomb, an aluminum honeycomb, a paper honeycomb, and a glass honeycomb.

Assignees

• Yokohama Rubber Co Ltd

Inventors

• Iwata Mitsuhiro
• Ito Tomohiro

Classifications

• B32B3/12

  characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure · CPC title

• B32B5/28

  impregnated with or embedded in a plastic substance {(not used)} · CPC title

• C08G59/20

  characterised by the epoxy compounds used · CPC title

• C08J2385/02

  containing phosphorus · CPC title

• C08J2461/06

  of aldehydes with phenols · CPC title