Expoxy resin composition excellent in weather resistance and fiber-reinforced composite materials

• US 20040031952A1
• Filed: 03/27/2003
• Published: 02/19/2004
• Est. Priority Date: 06/28/2001
• Status: Active Grant

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Murai, Shoji, Tanaka, Go, Oosedo, Hiroki, Kouchi, Shinji
• Granted Patent: US 6,902,811 B2
• Time in Patent Office: Days
• US Class Current: 252/588
• CPC Class Codes: C08G 59/24 carbocyclic
• CPC Class Codes: C08G 59/3218 Carbocyclic compounds
• CPC Class Codes: C08G 59/42 Polycarboxylic acids; Anhydrides, halides or low molecular weight esters thereof
• CPC Class Codes: C08G 59/4215 cycloaliphatic
• CPC Class Codes: H01L 23/293 Organic, e.g. plastic
• CPC Class Codes: H01L 23/295 containing a filler H01L23/296 takes precedence
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/24995 Two or more layers
• CPC Class Codes: Y10T 428/249952 At least one thermosetting synthetic polymeric material layer
• CPC Class Codes: Y10T 428/31511 Of epoxy ether

Abstract

The present invention relates to an epoxy resin composition comprising at least (A) an epoxy resin having a cycloalkane ring or cyclohexene ring but having neither aromatic ring nor aminic nitrogen atom, (B) a carboxylic anhydride having no aromatic ring, and (C) an ultraviolet absorbent, wherein a content of component (A) is from 70 to 100 percents by weight based on the total weight of epoxy resins, and a content of component (B) is from 70 to 100 percents by weight based on the total weight of carboxylic anhydrides.

By this constitution, the present invention can provide an epoxy resin composition whose cured product excels in mechanical properties and weatherability, and a fiber reinforced composite material having excellent mechanical properties and weatherability.

Claims

1. An epoxy resin composition comprising (A) an epoxy resin having a cycloalkane ring or a cyclohexene ring but having neither aromatic ring nor aminic nitrogen atom, (B) a carboxylic anhydride having no aromatic ring, and (C) an ultraviolet absorbent, wherein a content of component (A) is from 70 to 100 percents by weight based on the total weight of epoxy resins, and a content of component (B) is from 70 to 100 percents by weight based on the total weight of carboxylic anhydrides.

2. An epoxy resin composition according to claim 1, which comprises not more than 3 percents by weight, based on the weight of the epoxy resin composition, of an epoxy resin having an aromatic ring or an aminic nitrogen atom.

3. An epoxy resin composition according to claim 1, wherein the component (A) has 1,2-epoxycyclohexane ring or 1,2-epoxycyclopentane ring.

4. An epoxy resin composition according to claim 1, wherein the component (B) is a carboxylic anhydride having a cycloalkane ring or a cycloalkene ring.

5. An epoxy resin composition according to claim 1, wherein the component (C) has a molecular extinction coefficient in 380 nm in chloroform of from 5.0×

10² to 2.0×

10⁴.

6. An epoxy resin composition according to claim 1, wherein the component (C) is a benzotriazol ultraviolet absorbent.

7. An epoxy resin composition according to claim 1 which further comprises (D) an imidazole compound.

8. An epoxy resin composition according to claim 1 which further comprises (E) a polyol compound having neither aromatic ring nor aminic nitrogen atom.

9. An epoxy resin cured product obtained by curing an epoxy resin composition of claim 1.

23. A process for preparing a fiber reinforced composite material which comprises the steps of impregnating an epoxy resin composition of claim 1 into reinforcing fibers, and heating to cure the epoxy resin composition impregnated into the reinforcing fibers, characterized by impregnating the epoxy resin composition of claim 1 under the conditions that viscosity thereof is from 10 to 1000 mPa·

s.

24. A process for preparing a fiber reinforced composite material which comprises the steps of impregnating an epoxy resin composition of claim 1 into reinforcing fibers to obtain prepregs, thereafter laminating the prepregs to give a shape, and heating to cure the epoxy resin composition.

10. A fiber reinforced composite material comprising reinforcing fibers and a thermosetting matrix resin, which has a color difference Δ

E of not more than 4 in a 1500-hour weatherometer test by a sunshine carbon arc light without painting.

11. A fiber reinforced composite material according to claim 10, wherein the thermosetting matrix resin is an epoxy resin cured product of claim 9.

12. A fiber reinforced composite material according to claim 10, wherein the flexural modulus at room temperature of the thermosetting matrix resin is not less than 2.9 GPa.

13. A fiber reinforced composite material according to claim 10, wherein glass transition temperature of the thermosetting matrix resin is not less than 90 degrees Celsius.

14. A fiber reinforced composite material according to claim 10, wherein the reinforcing fibers are carbon fibers.

15. A fiber reinforced composite material which further comprises a transparent resin layer on an outside surface of a fiber reinforced composite material of claim 10.

16. A fiber reinforced composite material according to claim 15, which has a color difference Δ

E*ab of not more than 4 in a 1500-hour weatherometer test by a sunshine carbon arc light.

17. A fiber reinforced composite material according to claim 15, characterized by an average-of-roughness-height Ra in roughness measurement of a designed surface being from 0.05 to 2.0 micrometers.

18. A fiber reinforced composite material according to claim 15, characterized by a maximum height Ry in roughness measurement of a designed surface being from 0.1 to 5.0 micrometers.

19. A fiber reinforced composite material according to claim 15, characterized by an image clarity index NSIC of a designed surface being from 30 to 80 percents.

20. A fiber reinforced composite material according to claim 15, characterized by a pencil hardness of a designed surface being F or above.

21. A vehicle member comprising a fiber reinforced composite material of claim 15.

22. A sporting goods member comprising a fiber reinforced composite material of claim 10.