US6228474B1
Expired / Lapsed
US
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Epoxy resin composition for a fiber-reinforced composite material, yarn prepreg, and process and apparatus for preparing the same
Assignee: Toray Industries Inc
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Filing: 1997-02-21
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Granted: 2001-05-08
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Expires: 2017-02-21
Abstract
Abstract To provide an epoxy resin composition suitable as a matrix resin for fiber reinforcement, and a yarn prepreg suitable in unwindability, excellent in higher processability due to drapability, high in the tensile strength of the epoxy resin composition after curing, and high in efficiency of the strength of reinforcing fibers. A yarn prepreg, satisfying the following formulae (1) to (3): 50≦Wf≦80 (1) 20,000≦F≦100,000 (2) F/8,000≦d≦F/2,400 (3) where Wf is the content by weight of the fiber bundle (%), F is the number of filaments in the fiber bundle and d is the width of the prepreg (mm). An epoxy resin composition for a fiber reinforced composite material, comprising at least the following components [A], [B] and [C]: [A]: An epoxy resin mixture containing two or more epoxy resins, in such a manner that 100 weight parts of the epoxy resin mixture contains 40 to 79 parts of a monofunctional or bifunctional epoxy resin and 21 to 60 parts of a trifunctional or higher functional epoxy resin and that the epoxy resin mixture is 210 to 370 in epoxy equivalent weight [B]: Fine particles containing a rubber ingredient and insoluble in the epoxy resins [C]: A curing agent
Inventors
- 👤 Hajime Kishi
- 👤 Masazumi Tokunoh
- 👤 Tetsuyuki Kyono
- 👤 Fumiaki Noma
- 👤 Toyokazu Minakuchi
- 👤 Shoji Yamane
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 15:10
CPC Classifications
C; C08; C08G; C08G59/00; C08G59/18; C08G59/20; C08G59/32; C08G59/38; B; B29; B29B; B29B15/00; B29B15/08; B29B15/10; B29B15/12; B29B15/122; C04; C04B; C04B26/00; C04B26/02; C04B26/10; C04B26/14; C08G59/36; C08J; C08J5/00; C08J5/24; C08J5/241; C08J5/243; C08J5/249; B29K; B29K2063/00; C04B2111/00; C04B2111/00474; C04B2111/00896; C08J2363/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T428/00; Y10T428/249921; Y10T428/249924; Y10T428/249927; Y10T428/24994; Y10T428/249942; Y10T428/249945; Y10T428/249946
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
53 words
A yarn prepreg comprising a reinforcing fiber bundle and an epoxy resin, wherein the content by weight of the fiber bundle (%), Wf, the number of filaments in the fiber bundle, F, and the width of the prepreg (mm), d, satisfy the following formulae (1) to (3): 50≦Wf≦80 (1) 20,000≦F≦100,000 (2) F/8,000≦d≦F/2,400 (3).
Claim 2
Dependent Claim
53 words
A yarn prepreg comprising a reinforcing fiber bundle and an epoxy resin, wherein the content by weight of the fiber bundle (%), Wf, the number of filaments in the fiber bundle, F, and the width of the prepreg (mm), d, satisfy the following formulae (1) to (3): 50≦Wf≦80 (1) 20,000≦F≦100,000 (2) F/8,000≦d≦F/2,400 (3).
Claim 3
Dependent Claim
30 words
The yarn prepreg according to claim 1 , wherein the reinforcing fiber bundle is selected from the group consisting of carbon fibers, silicon carbide fibers, glass fibers and aramid fibers.
Claim 4
Dependent Claim
29 words
The yarn prepreg according to claim 2 , wherein the reinforcing carbon fiber bundle is a substantially twistless continuous carbon fiber bundle of 1.3 to 8.0 g/m in weight.
Claim 5
Dependent Claim
37 words
The yarn prepreg according to claim 2 , wherein the reinforcing carbon fiber bundle is continuous carbon fibers of 200 Gpa or more in tensile elastic modulus and 38,000 kJ/m 3 or more in fracture strain energy.
Claim 6
Dependent Claim
42 words
The yarn prepreg according to claim 1 , wherein the epoxy resin contains dicyandiamide as a curing agent, and the tensile breaking elongation of the resin obtained by heat-curing the epoxy resin at 130° C. for 2 hours is 5% or more.
Claim 7
Dependent Claim
42 words
The yarn prepreg according to claim 1 , wherein the epoxy resin contains diaminodiphenylsulfone as a curing agent, and the tensile breaking elongation of the resin obtained by heat-curing the epoxy resin at 180° C. for 2 hours is 5% or more.
Claim 8
Dependent Claim
23 words
The yarn prepreg according to claim 1 , wherein the interlaminar shear strength of its cured composite material is 65 to 140 MPa.
Claim 9
Dependent Claim
100 words
A yarn prepreg according to claim 1 or 2 , wherein the epoxy resin is an epoxy resin composition comprising: an epoxy resin mixture comprising two or more epoxy resins in such a manner that 100 weight parts of the epoxy resin mixture contains 40 to 79 parts of a monofunctional or bifunctional epoxy resin and 21 to 60 parts of a trifunctional or higher functional epoxy resin, the epoxy equivalent weight of the epoxy resin mixture being 210 to 370; fine particles comprising a rubber ingredient, the fine particles being insoluble in the epoxy resins; and a curing agent.
Claim 10
Dependent Claim
29 words
The yarn prepreg according to claim 8 , wherein the reinforcing carbon fiber bundle is a substantially twistless continuous carbon fiber bundle of 1.3 to 8.0 g/m in weight.
Claim 11
Dependent Claim
37 words
The yarn prepreg according to claim 9 , wherein the reinforcing carbon fiber bundle is continuous carbon fibers having tensile elastic modulus of 200 GPa or more and fracture strain energy of 38,000 kJ/m 3 or more.
Claim 12
Dependent Claim
28 words
An intermediate material for a fiber reinforced composite material, wherein a plurality of the yarn prepregs of claim 1 is arranged with their fiber axes kept in parallel.
Claim 13
Dependent Claim
23 words
The intermediate material for a fiber reinforced composite material according to claim 11 , wherein synthetic fibers are wound around said intermediate material.
Claim 14
Dependent Claim
15 words
A fiber reinforced composite material, obtained by curing the yarn prepreg of claim 8 .
Claim 15
Dependent Claim
17 words
A fiber reinforced composite material, wherein the intermediate material of claim 12 is twisted together and cured.
Claim 16
Dependent Claim
16 words
A concrete member, reinforced by the fiber reinforced composite material of claim 13 or 14 .
Claim 17
Dependent Claim
17 words
The yarn prepreg according to claim 1 , wherein the yarn prepreg satisfies the following formula: F/7,000≦d≦F/2,700.
Claim 18
Dependent Claim
17 words
The yarn prepreg according to claim 1 , wherein the yarn prepreg satisfies the following formula: F/6,000≦d≦F/3,000.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-05-07 | 2004-11-06 | 2005-05-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-05-07 | 2008-11-06 | 2009-05-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-05-07 | 2012-11-06 | 2013-05-08 | $7700.00 | Window Closed / Lapsed |