Fire-Retardant Resins and Composite Materials

Abstract

An epoxide resin for the manufacture of a fibre-reinforced composite material having fire retardant properties and/or for use as an adhesive or hot-melt adhesive having fire retardant properties, the epoxide resin being halogen-free and phenolic resin-free, the epoxide resin having: A. a mixture of (i) at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 and (ii) at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2; B. at least one catalyst for curing the mixture of epoxide-containing resins to form a cured epoxy resin; and C. a mixture of first, second and third fire retardant additives for reacting together to form an intumescent char when the cured epoxy resin is exposed to a fire, wherein (i) the first fire retardant additive comprises a blowing agent for generating a non-combustible gas, (ii) the second fire retardant additive comprises an acid donor for decomposing to form a phosphoric acid when the cured epoxy resin is exposed to a fire, and (iii) the third fire retardant additive comprises at least one or both of (a) a ceramic or glass material and (b) a ceramic or glass material precursor to form a ceramic or glass material when the cured epoxy resin is exposed to a fire.

Claims

1. An epoxide resin for the manufacture of a fibre-reinforced composite material having fire retardant properties and/or for use as an adhesive or hot-melt adhesive having fire retardant properties, the epoxide resin being halogen-free and phenolic resin-free, the epoxide resin comprising: A. a mixture of (i) at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 and (ii) at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2; B. at least one catalyst for curing the mixture of epoxide-containing resins to form a cured epoxy resin; and C. a mixture of first, second and third fire retardant additives for reacting together to form an intumescent char when the cured epoxy resin is exposed to a fire, wherein (i) the first fire retardant additive comprises a blowing agent for generating a non-combustible gas, (ii) the second fire retardant additive comprises an acid donor for decomposing to form a phosphoric acid when the cured epoxy resin is exposed to a fire, and (iii) the third fire retardant additive comprises at least one or both of (a) a ceramic or glass material and (b) a ceramic or glass material precursor for to form a ceramic or glass material when the cured epoxy resin is exposed to a fire.

2. An epoxide resin according to claim 1 wherein the first fire retardant additive comprises or consists of melamine.

3. An epoxide resin according to claim 1 wherein the first fire retardant additive is present in a concentration of from 3.5 to 6 wt %, or from 3.7 to 5.5 wt %, based on the weight of the epoxide resin.

4. (canceled)

5. An epoxide resin according to claim 1 wherein the second fire retardant additive comprises or consists of ammonium polyphosphate.

6. An epoxide resin according to claim 5 wherein the ammonium polyphosphate of the second fire retardant additive is present in a concentration of from 20 to 35 wt %, or from 27 to 32.5 wt %, or from 28.5 to 32 wt %, based on the weight of the epoxide resin.

7. (canceled)

8. An epoxide resin according to claim 1 wherein the third fire retardant additive comprises or consists of at least one of, or a mixture of any two or more of, the following: (i) a salt of a divalent metal cation and an oxoanion; (ii) a salt of a trivalent metal and an oxoanion; (iii) a glass material in particulate form; or (iv) a clay or ceramic material in particulate form.

9. An epoxide resin according to claim 8 wherein the third fire retardant additive comprises or consists of a salt of a zinc or calcium cation and an oxoanion selected from borate, molybdate, phosphate, phosphite, hypophosphite and hydroxyl stannate, the third fire retardant additive comprises or consists of a salt of aluminium and an oxoanion selected from borate, molybdate, phosphate, phosphite, hypophosphite and hydroxyl stannate, or the third fire retardant additive comprises or consists of an aluminosilicate clay in particulate form.

10. (canceled)

11. (canceled)

12. An epoxide resin according to claim 1 wherein the third fire retardant additive is present in a concentration of from 5 to 9 wt %, or from 6 to 8 wt %, or from 6.75 to 7.5 wt %, based on the weight of the epoxide resin.

13. (canceled)

14. (canceled)

15. An epoxide resin according to claim 1 wherein in the mixture of first, second and third fire retardant additives, the first, second and third fire retardant additives are present in a weight ratio of 1:6-6.5:1.3-1.7, or a weight ratio of 1:6.1-6.4:1.5-1.6.

16. (canceled)

17. An epoxide resin according to claim 1 wherein in the mixture of first, second and third fire retardant additives, the second and third fire retardant additives are present in a weight ratio of greater than 4:1 to up to 4.5:1.

18. An epoxide resin according to claim 1 wherein component A, the mixture of epoxide-containing resins, and component C, the mixture of first, second and third fire retardant additives, are present in a weight ratio of 52-68:32-48, or a weight ratio of 56-62:38-44.

19. (canceled)

20. An epoxide resin according to claim 1 wherein component C, the mixture of first, second and third fire retardant additives, provides the epoxide resin with a phosphorus content of from 7 to 10.5 wt %, or from 8 to 9.25 wt %, based on based on the weight of the epoxide resin.

21. (canceled)

22. An epoxide resin according to claim 1 wherein component C, the mixture of first, second and third fire retardant additives, provides the epoxide resin with a nitrogen content of from 5.8 to 8.25 wt %, or from 7 to 7.5 wt %, based on based on the weight of the epoxide resin.

23. (canceled)

24. An epoxide resin according to claim 1 wherein component A in the epoxide-resin has a viscosity of from 1.5 to 15 Pa.Math.s measured at a temperature of 85° C., measured using a viscometer sold under the trade name Brookfield CAP2000HT viscometer, with a cone number 3, a rotational velocity of 50 rpm, and for a period of 20 seconds, or from 2 to 10 Pa.Math.s, from 7 to 10 Pa.Math.s or from 2 to 7 Pa.Math.s measured under those conditions.

25. An epoxide resin according to claim 1 wherein in component A, the mixture of epoxide-containing resins comprises a blend comprising at least one first epoxide-containing resin which is solid at 20° C., and at least one second epoxide-containing resin which is liquid at 20° C., wherein the blend comprises from 20 to 40 wt % of at least one first epoxide-containing resin which is solid at 20° C., and from 10 to 30 wt % of at least one second epoxide-containing resin which is liquid at 20° C., each wt % being based on the weight of the epoxide resin, optionally the mixture of epoxide-containing resins further comprising from 5 to 15 wt %, based on the weight of the epoxide resin, of at least one third epoxide-containing resin which is semi-solid at 20° C.

26. An epoxide resin according to claim 25 wherein in component A, the mixture of epoxide-containing resins, the at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 is present in a concentration of from 8 to 12 wt %, or from 9 to 11 wt %, based on the weight of the epoxide resin.

27. An epoxide resin according to claim 1 wherein in component A, the mixture of epoxide-containing resins, the at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 comprises or consists of a solid bisphenol-A epoxy novolac resin.

28. An epoxide resin according to claim 1 wherein in component A the mixture of epoxide-containing resins, the at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2 is present in a concentration of from 45 to 52 wt %, or from 47 to 50 wt %, based on the weight of the epoxide resin.

29. (canceled)

30. An epoxide resin according to claim 1 wherein in component A, the mixture of epoxide-containing resins, the at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2 comprises or consists of a mixture of a solid bisphenol-A epoxy resin and a liquid bisphenol-A epoxy resin, optionally in addition an epoxy novolac resin.

31. An epoxide resin according to claim 30 wherein in the mixture of a solid bisphenol-A epoxy resin and a liquid bisphenol-A epoxy resin, optionally in addition an epoxy novolac resin, the solid bisphenol-A epoxy resin is present in a concentration of from 22 to 26 wt %, the liquid bisphenol-A epoxy resin is present in a concentration of from 12 to 17 wt %, and when present the epoxy novolac resin is present in a concentration of from 8 to 12 wt %, each based on the weight of the epoxide resin.

32. An epoxide resin according to claim 31 wherein in the mixture of a solid bisphenol-A epoxy resin and a liquid bisphenol-A epoxy resin, optionally in addition an epoxy novolac resin, the solid bisphenol-A epoxy resin is present in a concentration of from 23 to 25 wt %, the liquid bisphenol-A epoxy resin is present in a concentration of from 13 to 15 wt %, and when present the epoxy novolac resin is present in a concentration of from 9 to 11 wt %, each based on the weight of the epoxide resin.

33. An epoxide resin according to claim 1 which is free of any elastomeric material or elastomeric toughening additive.

34. An epoxide resin according to claim 1 wherein the at least one catalyst comprises plural catalysts, each having a respective curing temperature range, and the plural temperature ranges overlap to provide a cumulative curing temperature range for the epoxide-containing resin.

35. An epoxide resin according to claim 1 wherein the at least one catalyst for curing the epoxide-containing resin comprises or consists of a dicyanamide-based catalyst.

36. An epoxide resin according to claim 1 which is free of any epoxide-containing molecule that has been chemically reacted with a phosphinic acid derivative or dihydro-oxa-phospha-phenanthrene-oxide (DOPO).

37. An epoxide resin according to claim 1 further comprising at least one accelerator for the at least one catalyst, wherein the accelerator comprises an imidazole-based accelerator and/or a urea-based accelerator.

38. (canceled)

39. An epoxide resin according to claim 1 further comprising at least one anti-settling agent for the at least one mineral filler, wherein the at least one anti-settling agent comprises silicon dioxide, or amorphous silicon dioxide, or hydrophobic fumed silica, and wherein the at least one anti-settling agent is present in an amount of from 0.5 to 1.5 wt % based on the weight of the epoxide resin.

40. (canceled)

41. (canceled)

42. A prepreg comprising the epoxide resin of claim 1 and a fibrous reinforcement, wherein the epoxide resin forms an epoxide resin matrix which and at least partially impregnates the fibrous reinforcement.

43. A fibre-reinforced composite material produced from the prepreg of claim 42.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Embodiments of the present invention will now be described in greater detail by way of example only, with reference to the accompanying drawings, in which:

[0059] FIG. 1 is a graph produced by isothermal DSC testing showing the relationship between epoxide monomer conversion and time at various curing temperatures for an epoxide resin in accordance with an Example of the present invention;

[0060] FIG. 2 is a graph produced by isothermal DSC testing showing the relationship between epoxide monomer conversion, as a percentage of total enthalpy, and time at various curing temperatures for the epoxide resin tested in FIG. 1; and

[0061] FIG. 3 is a graph produced by isothermal DSC testing showing the relationship between epoxide monomer conversion, as a percentage of total enthalpy, and time at various curing temperatures for an epoxide resin in accordance with a Comparative Example not according to the present invention.

DETAILED DESCRIPTION

[0062] The present invention is predicated on the finding by the present inventors that the combination of (i) a specific epoxide-containing resin system to provide a low viscosity prior to curing and a high cross-link density after curing and (ii) a specific blend of three fire retardant fillers can provide the combination a cured epoxy resin with high quality fire-retardancy and structural properties, together with good processability and cost for the uncured epoxide resin.

[0063] In developing the fibre-reinforced composite material of the present invention, the present inventors aimed to employ an epoxide resin as the matrix resin for the composite material, and to select epoxide functionality to achieve a high cross-link density, which in turn enhances the toughness of the cured resin matrix, which otherwise would be significantly reduced by the addition of the fire retardant fillers. The cured epoxy resin matrix can bond satisfactorily to honeycomb cores for sandwich panel construction as used in interior panels incorporated into vehicles, such as aircraft and train, interiors.

[0064] The cured epoxy resin can also function as an adhesive to bond satisfactorily to a variety of substrates, for example also to be incorporated into vehicles, such as aircraft and train, interiors.

[0065] The fire retardance and smoke release characteristics of the epoxide resin can be significantly improved by the addition of the specific blend of three fire retardant fillers, and can be of a sufficient level to act as a global replacement for phenolic materials for such vehicle applications. This is a major technical and commercial advance.

[0066] However, a primary advantage of the present invention is that good FST properties can be achieved in an epoxy resin incorporating FST fillers, which nevertheless, despite the reasonably high filler content, provides good mechanical properties in the resultant cured epoxy resin composite material component.

[0067] The epoxide resin employed in accordance with the embodiments of the present invention is an addition-cured resin. Therefore no volatiles are released during cure. As compared to condensation-cured resins, such as phenolic resins, this provides the advantage of allowing components to be cured using lower-cost vacuum bag technology with significantly reduced refinishing and processing costs.

[0068] The epoxide resin employed in accordance with the embodiments of the present invention is a halogen-free, epoxide matrix resin and unlike phenolic systems, does not contain residual phenol or solvents. This means that it can be used in aircraft interior parts such as air-conditioning ducting without the risk of toxic phenol being leached into the passenger air supply. Its high toughness facilitates its application in aircraft flooring, previously the domain of toughened halogenated epoxides, with the additional advantage that the halogen-free, epoxide matrix resin avoids the smoke toxicity issues associated with halogenated epoxides.

[0069] Fire-retardant fillers were added to the epoxide resin matrix employed in accordance with the embodiments of the present invention to improve the smoke release and smoke toxicity properties of the matrix resin.

[0070] The present invention has particular application in the manufacture of multilaminar composite sandwich panels comprising a central core, for example of a honeycomb material itself known in the art, and two opposed outer plies comprising fibre-reinforced composite material incorporating a resin matrix produced in accordance with the present invention.

[0071] The resin matrix must display two main behaviours in order to achieve sufficient peel adhesion to a core such as a honeycomb core:

[0072] a. The matrix resin must flow sufficiently during cure in order to form sufficient contact area with the honeycomb cell surface to achieve good adhesion. Yet flow must be adequately ‘controlled’ to prevent excessive resin flow resulting in resin scarce areas of the prepreg laminate skins.

[0073] b. The matrix must exhibit toughness to withstand multiple impacts during service and resist premature matrix cracking, for example which would result in reduced peel strength.

[0074] The present inventors found that the use of a specific blend of multifunctional epoxide resins provided enhanced toughness in the resultant cured resin matrix as a result of cross-linking. Consequently, conventional elastomeric or thermoplastic toughening additives, such as a dispersed nitrile rubber in the resin matrix, can be avoided, which is advantageous since such additives would otherwise provide a source of carbon on combustion which would increase the smoke density.

[0075] The various components of the epoxide-resin matrix used in accordance with the preferred embodiments of the present invention are discussed in greater detail below.

Epoxide Component

[0076] The epoxide resin comprises a mixture of (i) at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 and (ii) at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2.

[0077] Preferably, the epoxide-containing resin mixture of component A in the epoxide-resin has a viscosity of from 1.5 to 15 Pa.Math.s measured at a temperature of 85° C., in particular measured using a viscometer sold under the trade name Brookfield CAP2000HT viscometer, with a cone number 3, a rotational velocity of 50 rpm, and for a period of 20 seconds. A preferred viscosity range for this parameter measured under these conditions is for example from 7 to 10 Pa.Math.s for manufacturing epoxy prepreg skins for honeycomb panels, for example for aerospace applications, and from 2 to 7 Pa.Math.s for manufacturing epoxy prepreg panels for railway applications. To prevent the addition of fillers increasing resin, the final resin viscosity is optimised by balancing the liquid epoxide functional resin to the higher-functionality epoxide resin blend

[0078] Preferably, in component A, the mixture of epoxide-containing resins comprises a blend comprising at least one first epoxide-containing resin which is solid at 20° C., and at least one second epoxide-containing resin which is liquid at 20° C., optionally further comprising at least one third epoxide-containing resin which is semi-solid. In this specification, the term “semi-solid” means materials which are neither true solids or true liquids but shares the properties of both states. Therefore a semi-solid resin cannot be poured in the same way as a liquid resin however will deform and flow under pressure or shear unlike a solid resin at 20° C.

[0079] Optionally, the blend comprises from 20 to 40 wt % of at least one first epoxide-containing resin which is solid at 20° C., and from 10 to 30 wt % of at least one second epoxide-containing resin which is liquid at 20° C., optionally further comprising from 5 to 15 wt % of at least one third epoxide-containing resin which is semi-solid at 20° C., each wt % being based on the weight of the epoxide resin.

[0080] Preferably, in the mixture of epoxide-containing resins, the at least one first non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of greater than 2 is present in a concentration of from 8 to 12 wt %, more preferably from 9 to 11 wt %, based on the weight of the epoxide resin. That resin may comprise or consist of a solid bisphenol-A epoxy novolac resin.

[0081] Preferably, in the mixture of epoxide-containing resins, the at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2 is present in a concentration of from 45 to 52 wt %, more preferably from 47 to 50 wt %, based on the weight of the epoxide resin. That resin may comprise or consist of a mixture of a solid bisphenol-A epoxy resin and a liquid bisphenol-A epoxy resin, optionally in addition an epoxy novolac resin. The solid bisphenol-A epoxy resin may be present in a concentration of from 22 to 26 wt %, the liquid bisphenol-A epoxy resin may be present in a concentration of from 12 to 17 wt %, and the optional epoxy novolac resin may be present in a concentration of from 8 to 12 wt %, each based on the weight of the epoxide resin. Alternatively, the solid bisphenol-A epoxy resin may be present in a concentration of from 23 to 25 wt %, the liquid bisphenol-A epoxy resin may be present in a concentration of from 13 to 15 wt %, and the optional epoxy novolac resin may be present in a concentration of from 9 to 11 wt %, each based on the weight of the epoxide resin.

[0082] Preferably, to achieve high FST properties the epoxide resin is free of any elastomeric material or elastomeric toughening additive. In particular, the epoxide-containing resin preferably is free of any toughening additives which comprise an elastomer and/or a thermoplastic having a molecule capable of reacting with the epoxide molecule so as to be chemically bonded as a co-monomer into the epoxide resin matrix. In contrast, the epoxide resin system is formulated to provide sufficient tack to the adhesive, hot-melt adhesive, or prepreg and to provide enhanced toughness of the cured epoxy resin.

[0083] In alternative embodiments for applications with lower FST requirements but requiring high toughness of the cured epoxy resin, such any elastomeric material or elastomeric toughening additive, or thermoplastic toughening additives may be present.

[0084] Suitable epoxy resins include diglycidyl ethers of bisphenol A, diglycidyl ethers of bisphenol F, epoxy novolac resins and N-glycidyl ethers, glycidyl esters, aliphatic and cycloaliphatic glycidyl ethers, glycidyl ethers of aminophenols, glycidyl ethers of any substituted phenols and blends thereof.

[0085] In a particularly preferred embodiment, the epoxide-containing resin is a solid at room temperature, 20 degrees Centigrade.

[0086] The epoxide-containing resin is formulated to comprise a mixture of solid and liquid resins, and optionally also semi-solid resins, so that when heated during curing the epoxide resin has a liquid content, resulting from liquefied epoxide resins and the associated catalyst system, and a solid content, resulting from the fillers, which has a reduced viscosity of the resin matrix to allow hot-melt processing, prepreg flexibility (drape) and sufficient prepreg tack to allow ease of handling.

[0087] The epoxide-containing resin may further comprise a catalyst carrier which acts to assist incorporation of the latent catalyst for the epoxide resin into the composition. Typically, the catalyst carrier comprises a diglycidyl ether of bisphenol F liquid resin. For example, the catalyst carrier may comprise a diglycidyl ether of bisphenol F liquid resin available in commerce under the trade name Epikote 862 from Resolution Performance Products. The catalyst carrier may typically be present in the resin composition in an amount of up to 10 wt %, based on the total weight of the resin composition.

[0088] Preferably, the epoxide resin is free of any epoxide-containing molecule that has been chemically reacted with a phosphinic acid derivative or dihydro-oxa-phospha-phenanthrene-oxide (DOPO).

Catalyst/Curing Agent Component

[0089] The epoxide-containing resin further comprises as a second component a catalyst or curing agent suitable for curing epoxide resins, optionally together with at least one additional catalyst additive or modifier. Any suitable catalyst may be used. The catalyst will be selected to correspond to the resin used. The catalyst may be accelerated. The catalyst or curing agent may typically be selected from a dicyandiamide, sulphanilamide, urone, urea, imidazole, amine, halogenated boron complex, anhydride, lewis base, phenolic novolac, or a nitrogen containing compound. Latent curing agents such as dicyandiamide, femurone and imidazole may be cured. Suitable accelerators include Diuron, Monuron, Fenuron, Chlortoluron, urea of toluene diisocyanate and other substituted homologues.

[0090] Preferably, the at least one catalyst for curing the epoxide-containing resin comprises or consists of a dicyanamide-based catalyst. Typically, the curing catalyst for the epoxide-containing resin is dicyandiamide, most preferably being in micronized form, and such a catalyst is available in commerce under the trade name Amicure CG1200E from Air Products Inc. Such a dicyandiamide-based catalyst has a high functionality to enable the resultant cured epoxy resin to have high cross-linking density and thereby a high glass transition temperature (Tg).

[0091] Optionally, the at least one catalyst comprises plural catalysts, each having a respective curing temperature range, and the plural temperature ranges overlap to provide a cumulative curing temperature range for the epoxide-containing resin.

[0092] The epoxide resin typically further comprises at least one accelerator for the at least one catalyst, for example an imidazole-based accelerator and/or a urea-based accelerator, typically a substituted/blocked urea. Such an imidazole-based accelerator can reduce the onset of reaction, thereby allowing curing at a reduced temperature. The imidazole-based accelerator preferably can be selected to provide a shelf life of the prepreg which is sufficiently long, for example >4 weeks at 21° C., to enable a useable shelf and storage life. Such a substituted/blocked urea can accelerate and control the curing profile.

[0093] The curing catalyst may typically be present in the resin composition in an amount of from 1 to 15 wt %, more typically from 6 to 12 wt %, based on the total weight of the epoxide component A of the resin composition. In one example, the catalyst is added at 4.9 wt % of the total composition of components A, B and C, which may correspond to 8.7 wt % of component A. Too low an amount of the curing catalyst may cause a reduced cure of the resin material, whereas too high an amount may cause an excessively exothermic cure.

[0094] The curing catalyst may be combined with an additional catalyst additive to reduce the activation energy, and hence the curing temperature, of the primary curing catalyst such as dicyandiamide. Such an additive may comprise urone, which has the chemical formula N,N″-(4-methyl-m-phenylene)bis[N′,N′-dimethylurea] and is available in commerce under the trade name Amicure UR2T from Evonik Industries Inc. or under the trade name UR500 from Alzchem AG.

[0095] Such an additive may typically be present in the resin composition in an amount of up to 15 wt %, more typically from 1 to 4 wt %, based on the total weight of the epoxide component A of the resin composition. In one example, the urone is added at 0.67 wt % of the total composition of components A, B and C, which may correspond to 1.18 wt % of component A. A low amount of the additional catalyst additive may cause a reduced cure speed and/or reduced curing temperature of the resin material, whereas too high an amount may cause reduced fire, smoke and toxicity resistance properties.

[0096] The curing catalyst may be yet further be combined with an additional additive imidazole-based catalyst or curing agent provided to further reduce the activation energy, and hence the curing temperature, of the urone. In addition, the C═N bonds present in imidazole have been shown to improve the fire-retardancy properties of the resultant cured epoxide-resin compared to other catalysts. Such an imidazole-based catalyst or curing agent is available in commerce under the trade name 2MZ-Azine-S from Shikoku, Japan.

[0097] The imidazole-based catalyst or curing agent may typically be present in the resin composition in an amount of up to 15 wt %, more typically from 1 to 4 wt %, based on the total weight of the epoxide component A of the resin composition. In one example, the imidazole-based catalyst is added at 2 wt % of the total composition of components A, B and C, which may correspond to 3.5 wt % of component A. A low amount of the imidazole-based catalyst or curing agent may cause a reduced cure speed and/or reduced curing temperature of the resin material, whereas too high an amount may cause an excessively exothermic cure.

Fire-Retardant/Smoke Suppressant Fillers

[0098] The epoxide resin comprises as a third component a mixture of first, second and third fire retardant additives for reacting together to form an intumescent char when the cured epoxy resin is exposed to a fire. These fire retardant additives comprises fillers used to promote fire-retardancy and/or reduce generation of smoke, opacity of smoke or toxicity of smoke.

[0099] Optionally, such fillers are dispersed homogeneously throughout the resin matrix. However, the dispersion may alternatively be heterogeneous, for example being present in surface layers. Many improvements in properties do not require such homogeneous dispersion and so this may result in a material which is thus either over-engineered for the application or, conversely, reduced in one or more other properties

[0100] The first fire retardant additive comprises a blowing agent for generating a non-combustible gas. Preferably, the first fire retardant additive comprises or consists of melamine. The first fire retardant additive may be present in a concentration of from 3.5 to 6 wt %, more preferably from 3.7 to 5.5 wt %, based on the weight of the epoxide resin.

[0101] The second fire retardant additive comprises an acid donor for decomposing to form a phosphoric acid when the cured epoxy resin is exposed to a fire, for example ammonium polyphosphate. Preferably, the ammonium polyphosphate of the second fire retardant additive is present in a concentration of from 20 to 35 wt %, more preferably from 27 to 32.5 wt %, still more preferably from 28.5 to 32 wt %, based on the weight of the epoxide resin. An ammonium polyphosphate fire retardant mineral filler is available under the trade name Exolit AP 422 from Clariant, Leeds, UK.

[0102] The third fire retardant additive comprises at least one or both of (a) a ceramic or glass material and (b) a ceramic or glass material precursor to form a ceramic or glass material when the cured epoxy resin is exposed to a fire.

[0103] Preferably, the third fire retardant additive comprises or consists of at least one of, or a mixture of any two or more of, the following: (i) a salt of a divalent metal cation and an oxoanion; (ii) a salt of a trivalent metal and an oxoanion; (iii) a glass material in particulate form; or (iv) a clay or ceramic material in particulate form.

[0104] In one preferred embodiment, the third fire retardant additive comprises or consists of a salt of a zinc or calcium cation and an oxoanion selected from borate, molybdate, phosphate, phosphite, hypophosphite and hydroxyl stannate. The third fire retardant additive may comprise or consist of a salt of aluminium and an oxoanion selected from borate, molybdate, phosphate, phosphite, hypophosphite and hydroxyl stannate. Alternatively, the third fire retardant additive may comprise or consist of an aluminosilicate clay in particulate form. One particular smoke suppressant mineral filler is zinc borate, available in commerce under the trade name Firebrake ZB from Borax Europe Limited.

[0105] In another preferred embodiment, the third fire retardant additive comprises or consists of a glass material in particulate form, for example glass microbeads having a diameter d(0.5) within the range of from 15 to 30 microns, and optionally a diameter d(0.9) within the range of from 30 to 80 microns.

[0106] In another preferred embodiment, the third fire retardant additive comprises or consists of a clay or ceramic material in particulate form, for example an aluminosilicate clay.

[0107] Preferably, the third fire retardant additive is present in a concentration of from 5 to 9 wt %, based on the weight of the epoxide resin, more preferably from 6 to 8 wt %, yet more preferably from 6.75 to 7.5 wt %, based on the weight of the epoxide resin.

[0108] Preferably, in the mixture of first, second and third fire retardant additives, the first, second and third fire retardant additives are present in a weight ratio of 1:6-6.5:1.3-1.7, typically a weight ratio of 1:6.1-6.4:1.5-1.6.

[0109] Preferably, in the mixture of first, second and third fire retardant additives, the second and third fire retardant additives are present in a weight ratio of greater than 4:1 to up to 4.5:1.

[0110] Preferably, the mixture of epoxide-containing resins, and the mixture of first, second and third fire retardant additives, are present in a weight ratio of 52-68:32-48, typically a weight ratio of 56-62:38-44.

[0111] Preferably, the mixture of first, second and third fire retardant additives, provides the epoxide resin with a phosporous content of from 7.5 to 10.5 wt %, more preferably from 8 to 9.25 wt %, based on based on the weight of the epoxide resin.

[0112] Preferably, the mixture of first, second and third fire retardant additives, provides the epoxide resin with a nitrogen content of from 5.8 to 8.25 wt %, %, more preferably from 7 to 7.5 wt % based on based on the weight of the epoxide resin.

[0113] The acid donor, for example ammonium polyphosphate, can act both in the condensed and gas phase during a fire. Ammonium polyphosphate decomposes at >240° C. releasing water and ammonia to cool and dilute the gaseous phase, and releasing phosphoric acid. The phosphoric acid acts as an acid catalyst in the dehydration of carbon-based poly-alcohols to form heat-unstable phosphate esters. The esters decompose to release carbon dioxide and phosphoric acid is regenerated. The carbonaceous char shields the substrate from attack by oxygen and radiant heat. In the gas phase, the release of non-flammable carbon dioxide helps to dilute the oxygen of the air and flammable decomposition products of the substrate. Any P* and PO* radicals liberated during the combustion can act as scavengers of oxygen radicals, thereby reducing the energy of the radicals in the gas phase and reducing volatilization.

[0114] The inorganic mineral fillers such as zinc borate act as a multifunctional fire retardant and smoke suppressant. The metal, e.g. zinc, species remains in the condensed phase and acts as a catalyst for char formation by promoting cross-linking in the expanded resin protective surface layer. Char formation in turn supresses smoke formation which is reinforced by the glass-forming ability of metal oxides, e.g. borate oxides, which can increase mechanical performance of char/intumescence.

[0115] The acid donor, for example ammonium polyphosphate, and the metal cation/oxyanion, for example zinc borate, interact synergistically whilst degrading, thereby stabilizing the phosphorus species.

[0116] Without being bound by any theory, it is believed by the present inventors that the glass beads work synergistically with the ammonium polyphosphate by the glass beads forming a fused/protective layer that minimises volatile/gas phase release. However typically, smoke density is also reduced through ant one or more of reduced carbon-carbon bond saturation (i.e. alkanes burn cleaner than alkenes), lower carbon content in the resin and by allowing complete combustion (i.e. ensuring CO.sub.2 rather than CO is formed).

[0117] The blowing agent, for example melamine, degrades at combustion temperatures, for example >300° C., thereby releasing nitrogen gas which forces the char formation to intumesce.

[0118] The weight ratio of the three fillers of the blend of first, second and third fire retardant additives can produce a strong, toughened intumescence which protects the polymeric substrate from further heat and oxygen, and traps volatiles to prevent further combustion.

[0119] If the fire retardant and smoke suppressant mineral fillers, are present in too high an amount, the resin composition may exhibit high viscosity, reduced toughness and poor adhesion, for example to a core, whereas if the fire retardant mineral filler is present in too low an amount, the fire, smoke and toxicity resistance properties may be reduced.

[0120] The mineral fillers may optionally be provided together with a filler dispersion additive to aid wetting and dispersion of fillers during manufacture of the matrix resin. Such a filler dispersion additive is available in commerce under the trade name BYK W980 from BYK Chemie, Wesel, Germany. The filler dispersion additive may typically be present in the resin composition in an amount of up to 1 wt %, based on the total weight of the resin composition.

Further Additives

[0121] The epoxide-containing matrix resin may comprise additional additives known in the art to improve resin processing or properties, or both.

[0122] In particular, an anti-settling agent may be provided to reduce or prevent settling of the at least one mineral filler, for example in the resin formulation during storage/processing and/or during curing of the resin. The anti-settling agent may also control resin flow during resin curing. In addition, such an agent can prevent settling of powder particles, such as the fire-retardant and/or smoke suppressant fillers. A typical anti-settling agent comprises silicon dioxide, optionally amorphous silicon dioxide, most typically hydrophobic fumed silica, for example available under the trade name Cabot TS-720. The at least one anti-settling agent is typically present in an amount of from 0.5 to 1.5 wt % based on the weight of the epoxide resin.

[0123] In a prepreg, the fibrous reinforcement may comprise one or more materials such as glass fibre, aramid fibre, carbon fibre, or PAN or pitch based carbon fibre. The present invention is particularly directed to an epoxide resin system which has sufficiently low viscosity during impregnation so that carbon fibres, which are generally harder to impregnate than glass fibres, can be reliably and uniformly impregnated to form a carbon-fibre prepreg.

[0124] The modified epoxide-containing matrix resin of preferred embodiments of the present invention may be used in prepregs and composite materials of the present invention, which in turn have particular application for use for interior panel construction for mass transport applications where a fire, smoke and toxicity requirement is necessary. The composite materials made using such a resin can provide significant advantages over the known resins discussed above, such as phenolic, cyanate-ester, SMC, modified vinyl-ester and halogenated epoxides which have been used in the past for these applications.

[0125] The epoxide-containing matrix resin of the preferred embodiments of the present invention may be used in a number of applications.

[0126] The epoxide-containing matrix resin of the preferred embodiments of the present invention may be used in structural applications where fire, smoke and toxicity performance that is similar to phenolic materials is required yet with greatly increased mechanical properties. Additional advantages include ease of processing and reduced refinishing which allow substantial cost reductions especially on large civil structures. Phenolic panels tend to be dark brown in colour and so are commonly painted to achieve the desired component colour. Problems can occur during service whereby if the material is scratched; the base colour of the phenolic becomes highly visible. The epoxide-containing matrix resin of the preferred embodiments of the present invention may be white in colour which reduces the visual impact of such scratching during use.

[0127] The modified epoxide-containing matrix resin of preferred embodiments of the present invention may alternatively be used in adhesives or hot-melt adhesives.

[0128] The resultant cured resins exhibit FST properties.

[0129] The epoxide-containing matrix resin of the preferred embodiments of the present invention can provide a number of technical benefits as compared to known prepregs and composite materials having fire and/or smoke resistance. In particular, there may be provided in accordance with the present invention: a phenol-free alternative to phenolic prepregs; good regulatory labelling for handling uncured material; halogen-free for reduced toxicity during combustion compared to brominated systems; no volatiles are released during cure—improved mechanical properties; can achieve increased filler loadings without forsaking processing capability or fibre wet-out; does not require high-pressure press tooling to process, can use low-cost vacuum-bag technology; can achieve an out-of-autoclave cure; high-quality surface finish “straight from tooling”—does not require expensive and time-consuming refinishing, no pitting, reduced time and cost to rework surface in post processing stages; higher reactivity allowing either lower temperature curing and/or faster curing compared to halogenated and DOPO modified systems; reduced material cost through use of lower cost chemistry; and pale-colour—requires less surface coating to achieve desired aesthetic and results in increased longevity during operation (i.e. scratches etc. are less visible).

[0130] The present invention can solve a number of problems associated with known fire retardant epoxide based structural prepregs, and in particular can provide the combination of high mechanical properties combined with excellent FST properties for an epoxy system using a specific blend of an intumescent filler system.

[0131] The modified epoxide material produced in accordance with the present invention may be used by manufactures of composite prepregs for use in a wide-range of fire-retardant applications. The prepreg would offer a unique alternative to a wide-range of existing fire-retardant materials including (but not limited to) phenolics, halogenated epoxides, and cyanate esters but with significant advantages of the combination of enhanced fire-retardant, smoke and toxicity (FST) properties and mechanical properties, together with good resin processing.

EXAMPLES

[0132] The epoxide-containing resin of the preferred embodiments of the present invention is further illustrated with reference to the following non-limiting examples.

[0133] The development of the epoxide-containing resin of the present invention required the determination of three discrete parameters essential for providing a fire retardant epoxy resin having high structural properties, namely high fire-retardancy, high smoke suppression and low toxicity. In addition to meeting these performance criteria, it was necessary to ensure that the epoxide-containing matrix resin was suitable for manufacture using hot-melt (non-solvent impregnation) impregnation methods. To benchmark the epoxide-containing matrix resin against current industry standards, the resin was tested to determine that it had thermal, mechanical and handling properties which complied with the specification established by Airbus Industries, Toulouse, France for interior FST materials, in particular (AIMS 05-10-034-01).

Example 1

[0134] A resin composition was formulated as set out in Table 1 (which had the applicant's product code SPX22703). The base epoxide resin comprised a blend of semi-solid, solid and liquid epoxide resin monomers of component A.

[0135] The base epoxide resin blend was mixed with the blend of ammonium polyphosphate, zinc borate and melamine fire retardant additives, which is component C, as set out in Table 1. The resin composition further comprised hydrophobic fumed silica as an anti-settling agent, sold under the trade name Cabot TS-720.

[0136] The resin composition further comprised, as component B and in wt % values with respect to the combination of components A, B and C, 2.25 wt % of dicyandiamide, in micronized form, as a primary resin curing catalyst, 0.67 wt % of urone as an additional catalyst additive to reduce primary catalyst activation energy, and 2.02 wt % of an imidazole-based catalyst additive to further reduce the primary catalyst activation energy.

[0137] The resin constituents liquefied on heating to 85° C. and component A had a viscosity of 5.5+/−0.6 Pa.Math.s measured at 85° C., and measured using a viscometer sold under the trade name Brookfield CAP2000HT viscometer, with a cone number 3, a rotational velocity of 50 rpm, and for a period of 20 seconds.

[0138] The base resin, comprising the combination of components A and C, i.e. the resin and fillers, had a base resin viscosity of 258+/−26 Pa.Math.s measured at 85° C., and measured using a viscometer sold under the trade name Brookfield CAP2000HT viscometer, with a cone number 3, a rotational velocity of 50 rpm, and for a period of 20 seconds.

[0139] The resin was used to make a prepreg, which comprised 46 wt % of the resin composition and 54 wt % of a glass fibre fabric with a satin weave, in particular a 7781 style 8H satin glass fabric, which was then cured.

[0140] The curing temperature was varied, and a series of isothermal differential scanning calorimetry (DSC) plots of the cure profile were measured. The results are shown in FIG. 1, and these plots show the speed of cure conversion at different curing temperatures.

[0141] FIG. 1 shows that there is a trend of increasing isothermal temperatures to reduce the time to 100% cure conversion, the latter parameter being the time to reach the maximum cure at a given cure temperature.

[0142] FIG. 2 correspondingly shows the actual cure conversion, calculated as a percentage of the total possible enthalpy observed in a dynamic DSC trace. As can be seen, a reduction in isothermal cure temperature, reduces the cure conversion, and therefore would increase the amount of residual uncured material within the resultant composite material laminate.

[0143] The resin system of Example 1 had a minimum cure temperature of 85° C., and a cure dwell time at that minimum cure temperature of 5 hours. Alternatively, when the resin system of Example 1 was subjected to a faster cure at a higher temperature of 120° C., the cure dwell time at the faster cure temperature was only 40 minutes.

[0144] One plot in FIG. 2 shows 80% cure conversion after 5 hours at 85° C.

[0145] The fire-retardancy of the prepreg resin of Example 1 in accordance with the present invention was tested in the laboratory for fire-retardant properties, in accordance with a number of industry standard FST tests. The tests were conducted by a UKAS-accredited fire testing agency external to the Applicant. The Maximum Average Rate of Heat Release MAHRE (kWm.sup.−2) and the Maximum Smoke Density (DSmax), smoke density being a dimensionless parameter, were measured, and categorised according to the EN45545 Rail Fire standard for exterior structural parts (R7) dependant on the use of train location (Overland train (HL1), Overland train with use of tunnels (HL2), Underground Trains (HL3)). The results are shown in Table 1.

[0146] It may be seen that the resin of Example 1 exhibited very low MAHRE, 37 kWm.sup.−2, and smoke density DSmax, 202, for an epoxide resin. The resin of Example 1 was found to pass the R7/HL3 specification.

Example 2

[0147] An alternative resin formulation as shown in Table 1 was used as Example 2 (which had the applicant's product code SPX25225). As compared to Example 1, primarily the modification was that glass microbeads were used instead of zinc borate. Additionally, the formulation comprised carbon Monarch, a carbon powder supplied by Cabot, which is also referred to as in the art as carbon black and is a common pigment for making black prepreg materials.

[0148] Again, it may be seen that the resin of Example 2 exhibited very low MAHRE, 36 kWm 2, and smoke density DSmax, 163, for an epoxide resin.

Example 3

[0149] An alternative resin formulation as shown in Table 1 was used as Example 3 (which had the applicant's product code SPX25211). As compared to Example 1, again glass microbeads were used instead of zinc borate. Additionally, the formulation comprised titanium dioxide as a whitening pigment.

[0150] Again, it may be seen that the resin of Example 3 exhibited very low MAHRE, 58 kWm.sup.−2, and smoke density DSmax, 67 for an epoxide resin.

[0151] The mechanical properties of the cured resin were tested. An 8 ply 7781 glass fabric monolithic panel was made and the Interlaminar Shear Strength (ILSS) was tested; the value was 58 MPa. The same panel was tested for flexural strength and flexural modulus; the value of flexural strength was 558 MPa and the value of flexural modulus was 20 GPa. Furthermore, a sandwich panel having a two ply skin with the same glass fabric was made and the Climbing Drum Peel Strength was tested; the value was 257 N/75 mm.

[0152] These tested FST and mechanical properties showed that the epoxide resin of the present invention, when used to form prepregs that are subsequently used to form fibre-reinforced cured epoxy resin matrix composite materials, for example in the form of panels, can exhibit good mechanical properties, in conjunction with good FST properties.

Comparative Example 1

[0153] In contrast, as a comparative example FIG. 3 shows an isothermal DSC cure conversion graph for the DOPO-based mixed resin system disclosed in the Applicant's earlier WO-A-2011/015611. The tested formulation is in Table 2 as Comparative Example 1. For that known DOPO-based mixed resin system, as can be seen from FIG. 3, the cure conversion is only <80% after 16 hours at 95° C. The known DOPO-based resin system had a minimum cure temperature of 95° C., and a cure dwell time at that minimum cure temperature of 16 hours. Alternatively, when the resin system of Comparative Example 1 was subjected to a faster cure at a higher temperature of 140° C., the cure dwell time at the faster cure temperature was 120 minutes.

[0154] In other words, the resin system of Example 1 provided a lower temperature and more complete cure that the known DOPO-based mixed resin system of Comparative Example 1.

[0155] Table 2 shows that the resin formulation of Comparative Example 1 exhibited unacceptably high MAHRE, 85 kWm.sup.−2, and smoke density DSmax, 756, for an epoxide resin.

Comparative Example 2

[0156] Referring to Table 2, Comparative Example 2 was an epoxide resin system that, as compared to Examples 1 and 2, included a resin system blend of epoxide resins that were unable to accommodate a large filler content system because the epoxide resins comprised a blend of only a semi-solid bisphenol-A epoxy resin and a solid bisphenol-A epoxy resin. The melamine, aluminium polyphosphate and zinc borate fillers as fire retardant additives were each present in a lower concentration than for the corresponding first, second and third fire retardant additives in Examples 1 and 2, because the higher resin viscosity in Comparative Example 2 limited the effective concentrations of these fillers that could be practically incorporated into the epoxide resin system. Table 2 shows that the resin formulation of Comparative Example 2 exhibited unacceptably high MAHRE, 55 kWm.sup.−2, and smoke density DSmax, 512, for an epoxide resin.

Comparative Example 3

[0157] In contrast to Example 3, the same panels were made using the same glass fabric and number of plies but instead of the epoxide resin of Example 3 a typical phenolic resin having FST properties was employed. The mechanical properties of the cured phenolic resin panels were tested. An 8 ply 7781 glass fabric monolithic panel was made and the Interlaminar Shear Strength (ILSS) was tested; the value was 34 MPa. The same panel was tested for flexural strength and flexural modulus; the value of flexural strength was 542 MPa and the value of flexural modulus was 24 GPa. Furthermore, a sandwich panel having a two ply skin with the same glass fabric was made and the Climbing Drum Peel Strength was tested; the value was 100 N/75 mm.

[0158] A comparison of the tested FST and mechanical properties for Example 3 and Comparative Example 3 showed that the epoxide resin of the present invention, when used to form prepregs that are subsequently used to form fibre-reinforced cured epoxy resin matrix composite materials, for example in the form of panels, can exhibit improved mechanical properties, in conjunction with good FST properties, and an overall improved performance as compared to phenolic resin panels. In particular, the improved mechanical properties as compared to the phenolic resin panel can enable a reduced weight epoxy resin panel to replace a phenolic resin panel with equivalent mechanical performance. Furthermore, the epoxide resin of the present invention also provides, as compared to phenolic resins, lower toxicity, since the epoxy resin is free of phenol and formaldehyde, improved surface finish and improved processing since the epoxy resin does not release water and/or volatile materials when curing.

TABLE-US-00001 TABLE 1 Example Example Example 1 2 3 SPX22703 SPX25225 SPX25211 Formulation-wt % Semi-solid 9.7 9.7 9.7 epoxy novolac resin Solid bisphenol-A 24.3 20.7 20.7 epoxy resin Solid 9.6 9.6 9.6 epoxy novolac resin Liquid bisphenol-A 14.5 18.1 18.1 epoxy resin Liquid bisphenol-F 0 0 0 epoxy resin Hydrophobic fumed 1.0 1.0 1.0 silica Carbon Monarch 0 0.2 0 Titanium dioxide 0 0 0.5 Melamine 4.7 4.7 4.6 Ammonium poly- 29.1 29.0 28.9 phosphate Zinc borate 7.1 0 0 Microperl ™ glass beads 0 7.0 6.9 Properties Resin functionality 3.3 3.3 3.3 Viscosity of base resin, 258 +/− 26 316 +/− 32 192 +/− 30 i.e. epoxy resin and filler components A and C, at 85° C.-Pa .Math. s Liquid to solid resin ratio- 0.6 0.9 0.6 by weight Melamine/APP/ZB or 1/6.2/1.5 1/6.2/1.5 1/6.3/1.5 glass bead weight ratio Resin/fillers in base resin- 58.1/41.9 58.1/41.9 58.1/41.9 by weight Weight ratio of 1.65 1.70 1.65 liquid (resin and catalyst)/ solid fillers Phosphorus content-wt % 9.2 9.1 9.1 Nitrogen content-wt % 7.4 7.4 7.3 MAHRE (kW/m.sup.2) 37 36 58 Smoke density (Ds max) 202 163 67

TABLE-US-00002 TABLE 2 Comparative Comparative Example 1 Example 2 Formulation-wt % Semi-solid bisphenol-A 44.6 43.3 epoxy resin Solid bisphenol-A 8.9 8.6 epoxy resin Hydrophobic fumed 1.0 1.0 Silica Aluminium trihydrate 15.6 0 filler Red phosphorous 21.9 21.3 Melamine 0 2.9 Ammonium 4.0 17.6 polyphosphate Zinc borate 4.0 5.3 Properties Melamine/APP/ZB weight 0/1/1 1/6.1/1.8 ratio Resin/fillers in base resin- 53.5/46.5 51.9/48.1 by weight Phosphorus content-wt % 1.3 5.5 Nitrogen content-wt % 0.6 4.5 MAHRE (kW/m.sup.2) 85 55 Smoke density (Ds max) 756 512