Matrix material

Patent metadata

Field	Value
Publication number	US-9670356-B2
Application number	US-201514965390-A
Country	US
Kind code	B2
Filing date	Dec 10, 2015
Priority date	Dec 11, 2014
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

A matrix material for a carbon fiber-reinforced composite comprises a matrix resin as a resin component. The matrix resin contains both a first epoxy resin and a second epoxy resin or only the first epoxy resin, further contains a third epoxy resin, and has an average epoxy equivalent weight of 109 to 162. The first epoxy resin contains a polyfunctional glycidylamine-type epoxy resin. The second epoxy resin contains at least one of a p-aminophenol-type epoxy resin and a tetramethylbiphenol-type solid epoxy resin. The third epoxy resin contains a bisphenol A-type epoxy resin having a weight-average molecular weight of 8000.

First claim

What is claimed is:

1. A matrix material for a carbon fiber-reinforced composite comprising a matrix resin, wherein
the matrix resin contains both of a first epoxy resin and a second epoxy resin or only the first epoxy resin, and further contains a third epoxy resin,
the first epoxy resin contains a polyfunctional glycidylamine-type epoxy resin having four epoxy groups in one molecule,
the second epoxy resin contains at least one of a p-aminophenol-type epoxy resin having three epoxy groups in one molecule and a tetramethylbiphenol-type solid epoxy resin having two epoxy groups in one molecule,
the third epoxy resin contains a bisphenol A-type epoxy resin having two epoxy groups in one molecule and having a weight-average molecular weight of 8000, and
the matrix resin has an average epoxy equivalent weight of 109 to 162, which is calculated using the following equation (A):
the average epoxy equivalent weight of the matrix resin=100/[(a weight percentage of the first epoxy resin [phr]/106)+(a weight percentage of the p -aminophenol-type epoxy resin [phr]/92)+(a weight percentage of the tetramethylbiphenol-type solid epoxy resin [phr]/177)+(a weight percentage of the third epoxy resin [phr]/1000)].

2. The matrix material according to claim 1 , wherein
the matrix resin contains 20 to 70 phr of the first epoxy resin, 20 to 75 phr of the second epoxy resin, and 5 to 20 phr of the third epoxy resin.

3. The matrix material according to claim 1 , wherein
the polyfunctional glycidylamine-type epoxy resin is represented by the following structural formula (1),
the p-aminophenol-type epoxy resin is represented by the following structural formula (2),
the tetramethylbiphenol-type solid epoxy resin is represented by the following structural formula (3),
the bisphenol A-type epoxy resin is represented by the following structural formula (4), and
the matrix resin contains 80 to 95 phr of an epoxy resin mixture of the polyfunctional glycidylamine-type epoxy resin and at least one of the p-aminophenol-type epoxy resin and the tetramethylbiphenol-type solid epoxy resin, and further contains 20 to 5 phr of the bisphenol A-type epoxy resin

4. The matrix material according to claim 3 , wherein
the epoxy resin mixture contains 20 to 70 phr of the polyfunctional glycidylamine-type epoxy resin and 75 to 20 phr of at least one of the p-aminophenol-type epoxy resin and the tetramethylbiphenol-type solid epoxy resin.

5. The matrix material according to claim 1 , further comprising 41 to 66 parts by weight of a hardener relative to 100 parts by weight of the matrix resin.

6. The matrix material according to claim 1 , wherein
the matrix material has a complex viscosity of 200 to 480 Pa·s at 50° C.

7. The matrix material according to claim 1 , wherein
the matrix material has an adhesive strength of 77 to 94 MPa to a carbon fiber measured by a microdroplet method.

8. A matrix material for an organic fiber-reinforced composite comprising a matrix resin, wherein
the matrix resin contains a first epoxy resin and a second epoxy resin,
the first epoxy resin contains a polyfunctional glycidylamine-type epoxy resin having four epoxy groups in one molecule,
the second epoxy resin contains a first bisphenol A-type epoxy resin having two epoxy groups in one molecule and having a weight-average molecular weight of 380, and further contains a second bisphenol A-type epoxy resin having two epoxy groups in one molecule and having a weight-average molecular weight of 900, and
the matrix resin has an average epoxy equivalent weight of 140 to 196, which is calculated using the following equation (a):
the average epoxy equivalent weight of the matrix resin=100/[(a weight percentage of the first epoxy resin [phr]/106)+(a weight percentage of the first bisphenol A -type epoxy resin [phr]/190)+(a weight percentage of the second bisphenol A -type epoxy resin [phr]/475)].

9. The matrix material according to claim 8 , wherein
the matrix resin contains 20 to 60 phr of the first epoxy resin and 40 to 80 phr of the second epoxy resin.

10. The matrix material according to claim 8 , wherein
the polyfunctional glycidylamine-type epoxy resin is represented by the following structural formula (5),
the first bisphenol A-type epoxy resin is represented by the following structural formula (6),
the second bisphenol A-type epoxy resin is represented by the following structural formula (7), and
the matrix resin contains 20 to 60 phr of the polyfunctional glycidylamine-type epoxy resin and 40 to 80 phr of the first bisphenol A-type epoxy resin and the second bisphenol A-type epoxy resin

11. The matrix material according to claim 10 , wherein
the matrix resin contains 20 to 60 phr of the first bisphenol A-type epoxy resin and 20 to 45 phr of the second bisphenol A-type epoxy resin.

12. The matrix material according to claim 8 , further comprising 30 to 43 parts by weight of a hardener relative to 100 parts by weight of the matrix resin.

13. The matrix material according to claim 8 , wherein
the matrix material has an adhesive strength of 77 to 94 MPa to an organic fiber measured by a microdroplet method.

Assignees

• Honda Motor Co Ltd
• Fukui Prefectural Government

Inventors

• Yoshida Shuichiro
• Kondo Keiichi

Classifications

• C08L63/00 Primary

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

• C08L2205/03

  containing three or more polymers in a blend · CPC title

• C08L2205/02

  containing two or more polymers of the same C08L -group · CPC title

• C08L2666/55

  Carbon · CPC title

• C08K7/06

  Elements · CPC title