Composite material with thermoplastic toughened novolac-based epoxy resin matrix
AssigneeHexcel Corporation
InventorsYan Zhu, Gordon Emmerson, Yen-Seine Wang, Maureen Boyle, Jessica Leandro
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Abstract
Pre-impregnated composite material (prepreg) that can be cured/molded to form aerospace composite parts. The prepreg includes carbon reinforcing fibers and an uncured resin matrix. The resin matrix includes an epoxy component that is a combination of a hydrocarbon epoxy novolac resin and a trifunctional epoxy resin and optionally a tetrafunctional epoxy resin. The resin matrix includes polyethersulfone as a toughening agent and a thermoplastic particle component.
Claims12
A pre-impregnated composite material comprising:
- A) reinforcing fibers comprising carbon fibers;
- and
- B) an uncured resin matrix comprising:
- a) an epoxy resin component comprising from 7 to 27 weight percent of a hydrocarbon epoxy novolac resin, based on the total weight of said uncured resin matrix, and from 26 to 36 weight percent of triglycidyl meta-aminophenol;
- b) 11 to 19 weight percent of a thermoplastic particle component based on the total weight of said uncured resin matrix, said thermoplastic component comprising thermoplastic particles that comprise a polyamide which is the polymeric condensation product of 1,10-decane dicarboxylic acid and an amine component having the formula
- where both R2 are hydrogen and both R1 are methyl or hydrogen;
- c) 7 to 12 weight percent of a thermoplastic toughening agent, based on the total weight of said uncured resin matrix, said thermoplastic toughening agent comprising polyethersulfone;
- and
- d) 17 to 27 weight percent of a curing agent, based on the total weight of said uncured resin matrix, said curing agent comprising 4,4′-diaminodiphenyl sulphone and/or 3,3′-diaminodiphenyl sulphone.
A method for making a pre-impregnated composite material that is curable to form a composite part, said method comprising the steps of:
- A) providing reinforcing fibers comprising carbon fibers;
- and
- B) impregnating said reinforcing fibers with an uncured resin matrix wherein said uncured resin matrix comprises:
- a) an epoxy resin component comprising from 7 to 27 weight percent of a hydrocarbon epoxy novolac resin, based on the total weight of said uncured resin matrix, and from 26 to 36 weight percent of triglycidyl meta-aminophenol;
- b) 11 to 19 weight percent of a thermoplastic particle component based or the total weight of said uncured resin matrix, said thermoplastic component comprising thermoplastic particles that comprise a polyamide which is the polymeric condensation product of 1,10-decane dicarboxylic acid and an amine component having the formula
- where both R2 are hydrogen and both R1 are methyl or hydrogen;
- c) 7 to 12 weight percent of a thermoplastic toughening agent, based on the total weight of said uncured resin matrix, said thermoplastic toughening agent comprising polyethersulfone;
- and
- d) 17 to 27 weight percent of a curing agent, based on the total weight of said uncured resin matrix, said curing agent comprising 4,4′-diaminodiphenyl sulphone and/or 3,3′-diaminodiphenyl sulphone.
Dependencies are inferred from the claim text.