Curable epoxy composition and a composite made therefrom

Patent metadata

Field	Value
Publication number	US-9834671-B2
Application number	US-201214436189-A
Country	US
Kind code	B2
Filing date	Nov 7, 2012
Priority date	Nov 7, 2012
Publication date	Dec 5, 2017
Grant date	Dec 5, 2017

Abstract

A curable epoxy resin composition including: (a) a cycloaliphatic epoxy resin, (b) an oxazolidone ring-containing epoxy resin, (c) a reaction product of (i) an anhydride compound and (ii) a polyol, and (d) an anhydride hardener; a process for preparing the curable epoxy resin composition; and a composite including a reinforcing fiber embedded in a thermoset resin, wherein the thermoset resin is a reaction product of the curable epoxy resin composition.

First claim

The invention claimed is:

1. A curable epoxy resin composition comprising: (a) a cycloaliphatic epoxy resin, (b) an oxazolidone ring-containing epoxy resin, (c) a reaction product of (i) an anhydride compound and (ii) a polyol, and (d) an anhydride hardener; wherein the reaction product (c) contains a carboxylic acid group and has an acid value of 40 to 60 mg KOH/g; wherein the polyol is an aliphatic polyol having an average molecular weight of 6,000 grams per mole or more; and wherein the composition exhibits no phase separation for at least eight hours at 25° C. after mixing.

2. A curable epoxy resin composition comprising: (a) a cycloaliphatic epoxy resin, (b) an oxazolidone ring-containing epoxy resin, (c) a reaction product of (i) an anhydride compound and (ii) a polyol, and (d) an anhydride hardener; wherein the reaction product (c) contains a carboxylic acid group and has an acid value of 40 to 60 mg KOH/g; wherein the polyol is an amphiphilic block copolymer having at least one hydroxyl functional group and having an average molecular weight of from 4,000 to 16,000 grams per mole; and wherein the composition exhibits no phase separation for at least eight hours at 25° C. after mixing.

3. The composition of claim 1 or claim 2 , comprising from 1 to 50 weight percent of the reaction product (c), where weight percentage is based on the total weight of the curable epoxy resin composition.

4. The composition of claim 1 or claim 2 , wherein the curable epoxy resin composition comprises from 50 to 95 weight percent of the cycloaliphatic epoxy resin and from 5 to 50 weight percent of the oxazolidone ring-containing epoxy resin, where weight percentage is based on the total epoxy resin weight in the composition.

5. The composition of claim 1 or claim 2 , wherein the oxazolidone ring-containing epoxy resin is a reaction product of an aromatic epoxy resin and an isocyanate compound.

6. The composition of claim 1 or claim 2 , wherein the anhydride compound or the anhydride hardener is independently selected from nardic maleic anhydride (NMA); methyltetrahydrophthalic anhydride (MTHPA); methylhexahydrophthalic anhydride (MHHPA); methyl-(endo)-5-norbornene-2,3-dicarboxylic anhydride; hexahydrophthalic anhydride (HHPA); tetrahydrophthalic anhydride (THPA); pyromellitic dianhydride; ciscyclopentanetetracarboxylic acid dianhydride; hemimellitic anhydride; trimellitic anhydride; naphthalene-1,8-dicarboxylic acid anhydride; phthalic anhydride; dichloromaleic anhydride; dodecenylsuccinic anhydride; glutaric anhydride; maleic anhydride; succinic anhydride and mixtures thereof.

7. The composition of claim 1 or claim 2 , further comprising an additional epoxy resin selected from diglycidyl ether of bisphenol A and derivatives, diglycidyl ether of bisphenol F and derivatives, phenol novolac epoxy resin, and mixtures thereof.

8. The composition of claim 1 or claim 2 , wherein the curable epoxy resin composition comprises 0.08 weight percent or less of a polyol, where weight percentage is based on the total weight of the curable epoxy resin composition.

9. A process for preparing the curable epoxy resin composition of claim 1 or claim 2 , comprising admixing (a) a cycloaliphatic epoxy resin, (b) an oxazolidone ring-containing epoxy resin, (c) a reaction product of (i) an anhydride compound and (ii) a polyol, and (d) an anhydride hardener.

10. A composite comprising a reinforcing fiber embedded in a thermoset resin, wherein the thermoset resin is a reaction product of the curable epoxy resin composition of claim 1 or claim 2 .

11. The composite of claim 10 , wherein the reinforcing fiber is a continuous fiber.

Assignees

• Dow Global Technologies Llc

Inventors

• Feng Yanli
• Qi Lejun
• Zhang Yi
• Du Wei

Classifications

• C08J5/04

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

• C08J2463/00

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

• C08J2363/00

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

• C08L63/00 Primary

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

• C08G59/42

  Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof · CPC title