Epoxy resin composition, intermediate substrate, and fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-12240975-B2
Application number	US-202017601813-A
Country	US
Kind code	B2
Filing date	Apr 1, 2020
Priority date	Apr 25, 2019
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

The purpose of the present invention is to provide an epoxy resin composition which exhibits a high level of deforming capacity and fracture toughness and from which a resin cured product maintaining heat resistance can be obtained. The epoxy resin composition according to the present invention satisfies condition 1 or condition 2 below, wherein the resin cured product obtained by reacting the epoxy resin composition at 150° C. for 60 minutes has a tensile elongation at break of 7% or more. Condition 1: including all the following components [A], [B], and [C], component [A]: a bifunctional aliphatic epoxy resin having a specific structure, component [B]: a terminal carboxy-modified acrylic rubber, and component [C]: a dicyandiamide. Condition 2: including the following components [D], [E], and [F] and satisfying conditions [a] and [b] below, component [D]: core-shell type rubber particles, component [E]: a boric ester compound, component [F]: a curing agent, condition [a]: including 9-18 parts by mass of component [D] with respect to 100 parts by mass of the total epoxy resin, and condition [b]: 0.003≤(the content of component [E]/the content of component [D])≤0.05.

First claim

The invention claimed is:

1. An epoxy resin composition satisfying condition 2 shown below, wherein a cured resin obtained by reacting the epoxy resin composition at 150° C. for 60 minutes has a tensile elongation at break of 7% or more and 20% or less:
condition 2: the epoxy resin composition includes components [D], [E], [F] and [H], and satisfies conditions [a] and [b] shown below,

wherein:
[D] is a core-shell rubber particle;
[E] is a boric acid ester compound;
[F] is a curing agent; and
[H] is an aromatic urea compound,
condition [a]: the epoxy resin composition includes 9 to 18 parts by mass of the component [D] per 100 parts by mass of total epoxy resin; and
condition [b]: 0.003≤ (content of the component [E]/content of the component [D]) ≤0.05.

2. The epoxy resin composition according to claim 1 , wherein the epoxy resin composition has a difference in glass transition temperature of 20° C. or less after being stored at 40° C. and 75% RH for 14 days in the condition 2.

3. The epoxy resin composition according to claim 1 , comprising:
2 to 10 parts by mass of a triblock copolymer component per 100 parts by mass of total epoxy resin in the condition 2; and
40 to 70 parts by mass of component [G]: a dicyclopentadiene type-epoxy resin per 100 parts by mass of total epoxy resin.

4. An intermediate base material comprising a reinforcing fiber impregnated with the epoxy resin composition according to claim 1 .

5. A fiber-reinforced composite material comprising a cured product of the intermediate base material according to claim 4 .

Assignees

• Toray Industries

Inventors

• Konishi Daisuke
• Yamakita Yuichi
• Hanabusa Hideki
• Hirano Noriyuki
• Tsuzuki Masahiro

Classifications

• C08J5/04

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• C08G59/72

  Complexes of boron halides · CPC title

• C08G59/50

  Amines · CPC title

• C08G59/22 Primary

  Di-epoxy compounds · CPC title

• C08J5/10

  characterised by the additives used in the polymer mixture · CPC title