Epoxy resin composition for fiber-reinforced composite material, prepreg and fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-10266641-B2
Application number	US-201515507929-A
Country	US
Kind code	B2
Filing date	Jul 16, 2015
Priority date	Sep 2, 2014
Publication date	Apr 23, 2019
Grant date	Apr 23, 2019

Abstract

Provided are: an epoxy resin composition for fiber-reinforced composite materials, which has a good balance between storage stability and fast curing properties at high levels; a prepreg; and an epoxy resin composition which exhibits excellent mechanical characteristics as a fiber-reinforced composite material. A resin composition which contains an epoxy resin, dicyandiamide, an imidazole compound and an acidic compound, while satisfying the following conditions (a)-(c):
(d) The time until the heat flow rate reaches the peak top after the epoxy resin composition reaches 100° C. is 25 minutes or less as measured by a differential scanning calorimeter at an isothermal temperature of 100° C. in a nitrogen gas stream. (e) The time until the heat flow rate reaches the peak top after the epoxy resin composition reaches 60° C. is 15 hours or more as measured by a differential scanning calorimeter at an isothermal temperature of 60° C. in a nitrogen gas stream. (f) The ratio of the number of epoxy groups to the number of imidazole rings in the epoxy resin composition is from 25 to 90 (inclusive).

First claim

The invention claimed is:

1. A prepreg for fiber-reinforced composite material comprising reinforcement fibers and an epoxy resin composition, wherein the epoxy resin composition comprises the following components [A], [B], [C], and [D]:
[A] an epoxy resin having an average epoxy equivalent weight of from at least 250 g/eq to up to 500 g/eq,
[B] a dicyandiamide,
[C] an imidazole compound represented by the general formula (II):

wherein R5, R6, R7, and R8 are each independently a hydrogen atom, an aliphatic hydrocarbon group containing 1 to 20 carbon atoms, or a phenyl group, and Y is a single bond, an alkylene group, an alkylidene group, an ether group, or a sulfonyl group, and
[D] a borate ester as an acidic compound,
wherein the epoxy resin composition satisfies the following conditions [a], [b], and [c]:
[a] time interval between reaching to 100° C. and reaching of the heat flow to the top of the peak is up to 25 minutes when the epoxy resin composition is isothermally analyzed at 100° C. by using a differential scanning colorimeter in nitrogen stream,
[b] time interval between reaching to 60° C. and reaching of the heat flow to the top of the peak is at least 15 hours when the epoxy resin composition is isothermally analyzed at 60° C. by using a differential scanning colorimeter in nitrogen stream, and
[c] ratio of the number of the epoxy groups to the number of imidazole rings in the epoxy resin composition is at least 25 and up to 90.

2. A prepreg according to claim 1 wherein the component [C] is dissolved in the epoxy resin composition.

3. The prepreg according to claim 1 , wherein the borate ester is selected from the group consisting of alkyl borates, aromatic borates, and cyclic borates.

4. The prepreg according to claim 1 , wherein the borate ester is selected from the group consisting of trimethyl borate, triethyl borate, tributyl borate, tri-n-octyl borate, tri(triethylene glycol methyl ether) borate, tricyclohexyl borate, trimenthyl borate, tri-o-cresyl borate, tri-m-cresyl borate, tri-p-cresyl borate, triphenyl borate, tri(1,3-butanediol) biborate, tri(2-methyl-2,4-pentanediol) biborate, trioctylene glycol diborate, tris-o-phenylene bisborate, bis-o-phenylene pyroborate, bis-2,3-dimethylethylene phenylene pyroborate, and bis-2,2-dimethyltrimethylene pyroborate.

5. A prepreg according to claim 1 , wherein the reinforcement fibers include carbon fibers.

6. A fiber-reinforced composite material produced by curing the prepreg according to claim 1 .

Assignees

• Toray Industries

Inventors

• Takaiwa Reo
• Sano Kentaro
• Hirano Noriyuki

Classifications

• C08J2363/04

  Epoxynovolacs · CPC title

• C08J2363/02

  Polyglycidyl ethers of bis-phenols · CPC title

• C08J2363/00

  Characterised by the use of epoxy resins; Derivatives of epoxy resins · CPC title

• C08G59/686

  containing nitrogen · CPC title

• C08J5/042

  with carbon fibres · CPC title