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

Patent metadata

Field	Value
Publication number	US-11745485-B2
Application number	US-202017072110-A
Country	US
Kind code	B2
Filing date	Oct 16, 2020
Priority date	Apr 23, 2018
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

An epoxy resin composition for carbon-fiber-reinforced composite material includes (A) a bisphenol F-type epoxy resin that is liquid at 25° C., (B) a polyfunctional amine-type epoxy resin, and (C) 3,3′-Diaminodiphenyl sulfone. With respect to 100 parts by mass of the entire epoxy resin in the epoxy resin composition, the content of component (A) is 40 to 60 parts by mass, the content of component (B) is 30 to 45 parts by mass, and the total content of components (A) and (B) is 85 to 100 parts by mass. The content of component (C) satisfies 1.04≤x/y≤1.35, where x is a molar number of active hydrogen atoms in the amine of component (C) and y is a molar number of all epoxy groups in the epoxy resin composition.

First claim

The invention claimed is:

1. A carbon fiber prepreg, comprising:
an epoxy resin composition comprising the follow components (A)-(C):
a component (A): bisphenol F epoxy resin that is liquid at 25° C.,
a component (B): at least one of tetraglycidyl diaminodiphenylmethane and triglycidyl aminophenol, and
a component (C): 3,3′-diaminodiphenyl sulfone;

sheet of carbon fiber base material; and
fusible polyamide resin particles,
wherein
with respect to 100 parts by mass of all epoxy resins in the epoxy resin composition, a sum of a content of the component (A) and a content of the component (B) is 85 to 100 parts by mass, the content of the component (A) is 40 to 60 parts by mass, and the content of the component (B) is 30 to 45 parts by mass; and
a content of the component (C) satisfies Expression (1):
1.04≤ x/y≤ 1.35  (1)

where x is a molar number of active hydrogen atoms in an amine in the component (C) and y is a molar number of all epoxy groups in the epoxy resin composition.

2. The carbon fiber prepreg according to claim 1 , wherein the content of the component (C) satisfies 1.04≤x/y≤1.31.

3. The carbon fiber prepreg according to claim 1 , wherein a content of the fusible polyamide resin particles is 5 to 25 parts by mass with respect to 100 parts by mass of the epoxy resin composition.

4. The carbon fiber prepreg according to claim 1 , wherein the fusible polyamide resin particles have a melting point of 140° C. to 180° C.

5. The carbon fiber prepreg according to claim 1 , wherein the fusible polyamide resin particles have a glass transition temperature of 140° C. to 180° C.

6. The carbon fiber prepreg according to claim 1 , wherein the fusible polyamide resin particles are unevenly distributed on a surface of the carbon fiber prepreg.

7. A hardened product of a laminate, comprising:
two or more laminated sheets of the carbon fiber prepreg according to claim 1 .

8. A composition, comprising:
an epoxy resin composition comprising the following components (A)-(C):
a component (A): bisphenol F epoxy resin that is liquid at 25° C.,
a component (B): at least one of tetraglycidyl diaminodiphenylmethane and triglycidyl aminophenol, and
a component (C): 3,3′-diaminodiphenyl sulfone; and

fusible polyamide resin particles,
wherein
with respect to 100 parts by mass of all epoxy resins in the epoxy resin composition, a sum of a content of the component (A) and a content of the component (B) is 85 to 100 parts by mass, the content of the component (A) is 40 to 60 parts by mass, and the content of the component (B) is 30 to 45 parts by mass; and
a content of the component (C) satisfies Expression (1):
1.04≤ x/y≤ 1.35  (1)

where x is a molar number of active hydrogen atoms in an amine in the component (C) and y is a molar number of all epoxy groups in the epoxy resin composition.

9. The composition according to claim 8 , wherein the content of the component (C) satisfies 1.04≤x/y≤1.31.

10. The composition according to claim 8 , wherein a hardened product of the composition has a water absorption rate of 3.3% or less.

11. The composition according to claim 8 , wherein the component (B) is a mixture of triglycidyl aminophenol and tetraglycidyl diaminodiphenylmethane.

12. The composition according to claim 11 , wherein a mass ratio of triglycidyl aminophenol to tetraglycidyl diaminodiphenylmethane in the mixture is less than or equal to 2.

13. A carbon fiber prepreg, comprising:
the composition according to claim 8 ; and
a carbon fiber.

14. A carbon-fiber-reinforced composite material, comprising:
an epoxy resin composition comprising the following components (A)-(C):
a component (A): bisphenol F epoxy resin that is liquid at 25° C.,
a component (B): at least one of tetraglycidyl diaminodiphenylmethane and triglycidyl aminophenol, and
a component (C): 3,3′-diaminodiphenyl sulfone;

plural sheets of carbon fiber base material that are laminated; and
polyamide resin particles that are fused and solidified and are present between layers of the plural sheets of the carbon fiber base material,
wherein
with respect to 100 parts by mass of all epoxy resins in the epoxy resin composition, a sum of a content of the component (A) and a content of the component (B) is 85 to 100 parts by mass, the content of the component (A) is 40 to 60 parts by mass, and the content of the component (B) is 30 to 45 parts by mass; and
a content of the component (C) satisfies Expression (1):
1.04 ≤x/y≤ 1.35  (1)

where x is a molar number of active hydrogen atoms in an amine in the component (C) and y is a molar number of all epoxy groups in the epoxy resin composition.

15. The carbon-fiber-reinforced composite material according to claim 14 , wherein the content of the component (C) satisfies 1.04≤x/y≤1.31.

Assignees

• Mitsubishi Chem Corp

Inventors

• Harada Yukihiro
• Nohara Atsushi

Classifications

• B32B27/38 Primary

  comprising epoxy resins · CPC title

• C08J5/243

  using carbon fibres · CPC title

• C08J5/248

  using pre-treated fibres · CPC title

• C08L63/00

  Compositions of epoxy resins; Compositions of derivatives of epoxy resins · CPC title

• B32B2262/106

  Carbon fibres, e.g. graphite fibres · CPC title