Toray Industries, Inc.

Alfred P Haro

Nobuyuki Arai

Kenichi Yoshioka

Felix N Nguyen

Jonathan C Hughes

Atsuhito Arai

Norimitsu Natsume

Swezin Than Tun

Toshiya Kamae

Jeffrey A Satterwhite

Benjamin Lehman

Jonathan Hughes

Andrew Hideo Koyanagi

Katrina P Vizzini

Bradley R Fenbert

This invention relates to a flame retardant epoxy resin composition which includes an epoxy resin structure having an epoxy functionality of 2 or more with a measured total heat release value of not more than 23 kJ/g as well as an organic phosphinic acid structure (in reacted or unreacted form), as well as a prepreg, and a fiber reinforced composite material prepared using the epoxy resin composition. More specifically, an epoxy resin composition is provided that contains a combination of particular types of epoxy resins and curatives that provide sufficient flame retardance when cured at 163° C. for 15 minutes. The epoxy resin systems are also suitable for preparing a fiber-reinforced composite material that will also provide sufficient flame retardance for a variety of applications.

Flame retardant epoxy resin composition

A laminate body is provided which contains a thin prepreg having a component (A) containing a matrix of reinforcing fiber, a component (B) containing a thermosetting resin, and a component (C) containing particles of a thermoplastic resin. When molded and cured out of autoclave, the laminate body achieves a fiber-reinforced composite having a low void ratio and providing excellent mechanical performance.

Prepreg, laminate body, fiber-reinforced composite material, and manufacturing method for fiber-reinforced composite material

A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.

Prepreg, laminate body, fiber reinforced composite material, and manufacturing method for fiber reinforced composite material

A prepreg comprising a layer of impregnated reinforcing fibers comprising at least one layer of reinforcing fibers impregnated by a resin composition comprising at least a thermosetting resin, a curing agent and an accelerator, such that the accelerator has a gradient concentration which is more concentrated in the resin composition in the vicinity of the reinforcing fibers than further away. The resin composition comprising a first resin composition impregnates the reinforcing fibers to provide a layer of impregnated reinforcing fibers and a surface layer comprising a second resin composition is formed on the layer of impregnated reinforcing fibers, wherein the first resin composition has at least one peak exotherm occurring at a time earlier than and/or at a temperature lower than any peak exotherm of the second resin composition. The heat generation from the first resin composition is tailored to initiate or speed up the curing of the second resin composition, leading to a substantial reduction of cure cycle time of the prepreg. Excellent handling and processing abilities of the uncured prepreg and excellent physical, thermal and mechanical properties when cured are achieved.

Prepreg with variable cure rate resin composition

Embodiments herein relate to a prepreg comprising a thermosetting resin, and reinforcing fibers in the thermosetting resin, wherein when the prepreg is cured in vacuum bag only conditions, and a method of making the same. The method also applies for autoclave processing. Embodiments also relate to a cured fiber reinforced composite material made by thermally curing the prepreg.

Prepreg, fiber reinforced composite material, and manufacturing method for fiber reinforced composite material

An epoxy resin composition having components (A), (B), (C), and (D), wherein the epoxy resin composition has a viscosity at 40&#xb0; C. of about 1&#xd7;10to about 1&#xd7;10Pa&#xb7;s, a curing start temperature of about 90 to about 110&#xb0; C., and a minimum viscosity at the curing start temperature of about 2 to about 20 Pa&#xb7;s, wherein the components (A), (B), (C), and (D) are as follows: (A) About 60 weight parts or more of a tetraglycidyl amine type epoxy resin per 100 weight parts of the epoxy resin blend; (B) Dicyandiamide; (C) Diaminodiphenyl sulfone and (D) Urea compound.

Epoxy resin composition for fiber reinforced composite material, prepreg, and fiber reinforced composite material

A fiber reinforced polymer composition is provided comprising a fiber and an adhesive composition, wherein the adhesive composition comprises at least a thermosetting resin, a curing agent, and a hard interfacial material. When cured, the adhesive composition forms good bonds to the reinforcing fiber, and an interfacial region between the reinforcing fiber and the adhesive composition is formed which comprises the hard interfacial material. Additional embodiments include a prepreg and a method of manufacturing a composite article by curing the adhesive composition and the reinforcing fiber.

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Tacoma, WA, United States of America

Alfred P Haro