Curable resin composition, and film, molded article, prepreg, and fiber-reinforced plastic using said curable resin composition

Abstract

A curable resin composition including components (A), (B), (C) and (D) below: component (A): a bisphenol epoxy resin with a softening point of 80° C. or more, component (B): a bisphenol epoxy resin which is liquid at 25° C., component (C): a bi- or more-functional (meth)acrylate compound, and component (D): a curing agent.

1 - 19 . (canceled) 
     
     
         20 . A prepreg comprising reinforcing fibers and a matrix resin, wherein:
 the reinforcing fibers are impregnated with the matrix resin,   the prepreg is in the form of a sheet, and   the matrix resin is a resin composition comprising an epoxy resin and components (C) and (D) below:   component (C): a bi- or more-functional (meth)acrylate monomer, and   component (D): a curing agent comprising at least one component (d1) selected from the group consisting of a dicyandiamide, a urea, and an imidazole, and at least one component (d2) which is a radical polymerization initiator.   
     
     
         21 . The prepreg according to  claim 20 , which further comprises component (H): an oxazolidone ring-containing epoxy resin. 
     
     
         22 . The prepreg according to  claim 20 , wherein the component (C) comprises at least one monomer selected from the group consisting of neopentyl glycol diacrylate, polyethylene glycol dimethacrylate, trimethylolpropane trimethacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, dioxane glycol diacrylate, isocyanuric acid EO-modified di- and tri-acrylates, 2-[5-ethyl-5-[(acryloyloxy)methyl]-1,3-dioxane-2-yl]-2,2-dimethylethyl acrylate, dimethylol-tricyclodecane diacrylate. 
     
     
         23 . The prepreg according to  claim 20 , wherein the component (d2) is at least one peroxide compound selected from the group consisting of methyl ethyl ketone peroxide, methyl cyclohexanone peroxide, methyl acetoacetate peroxide, acetylacetone peroxide, 1,1-bis(t-butylperoxy)3,3,5-trimethylcyclohexane, 1,1-bis(t-hexylperoxy)cyclohexane, 1,1-bis(t-hexylperoxy)3,3,5-trimethylcyclohexane, 1,1-bis(t-butylperoxy)cyclohexane, 2,2-bis(4,4-di-t-hexylperoxycyclohexyl)propane, 1,1-bis(t-butylperoxy)cyclododecane, n-butyl 4,4-bis(t-butylperoxy)valerate, 2,2-bis(t-butylperoxy)butane, 1,1-bis(t-butylperoxy)-2-methylcyclohexane, t-butyl hydroperoxide, P-menthane hydroperoxide, 1,1,3,3-tetramethylbutyl hydroperoxide, t-hexyl hydroperoxide, dicumyl peroxide, 2,5-dimethyl-2,5-bis(t-butyl)peroxy)hexane, α,α′-bis(t-butylperoxy)diisopropylbenzene, t-butylcumyl peroxide, di-t-butyl peroxide, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexyne-3, isobutyryl peroxide, 3,5,5-trimethylhexanoyl peroxide, octanoyl peroxide, lauroyl peroxide, cinnamate peroxide, m-toluoyl peroxide, benzoyl peroxide, diisopropyl peroxydicarbonate, bis(4-t-butylcyclohexyl)peroxydicarbonate, di-3-methoxybutylperoxydicarbonate, di-2-ethylhexylperoxydicarbonate, di-sec-butylperoxydicarbonate, di(3-methyl-3-methoxybutyl)peroxydicarbonate, di(4-t-butylcyclohexyl)peroxydicarbonate, α,α′-bis(neodecanoylperoxy)diisopropylbenzene, cumylperoxyneodecanoate, 1,1,3,3-tetramethylbutylperoxyneodecanoate, 1-cyclohexyl-1-methylethylperoxyneodecanoate, t-hexylperoxyneodecanoate, t-butylperoxyneodecanoate, t-hexyperoxypivalate, t-butylperoxypivalate, 2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)hexane, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate, 1-cyclohexyl-1-methylperoxy-2-ethylhexanoate, t-hexylperoxy-2-ethylhexanoate, t-butylperoxy-2-ethyl hexanoate, t-butylperoxyisobutyrate, t-butylperoxymaleic acid, t-butylperoxylaurate, t-butylperoxy-3,5,5-trimethylhexanoate, t-hexylperoxyisopropyl monocarbonate, t-butylperoxyisopropyl monocarbonate, t-butylperoxy-2-ethylhexyl monocarbonate, 2,5-dimethyl-2,5-bis(benzoylperoxy)hexane, t-butylperoxyacetate, t-hexylperoxybenzoate, t-butylperoxy-m-toluoylbenzoate, t-butylperoxybenzoate, bis(t-butylperoxy)isophthalate, t-butylperoxyallyl monocarbonate, 3,3′, 4,4′-tetra(t-butylperoxycarbonyl)benzophenone, di-t-hexyl peroxide, and diisopropylbenzene hydroperoxide. 
     
     
         24 . The prepreg according to  claim 20 , wherein the component (d1) is contained in an amount of 1 to 15 parts by mass with respect to 100 parts by mass of a total of all epoxy resins contained in the resin composition. 
     
     
         25 . The prepreg according to  claim 20 , wherein the component (d2) is contained in an amount of 0.1 to 5 parts by mass with respect to 100 parts by mass of a total of all epoxy resins and all (meth)acrylate monomers contained in the resin composition. 
     
     
         26 . The prepreg according to  claim 20 , wherein the component (C) is contained in an amount of 5 to 45 parts by mass with respect to 100 parts by mass of a total of all epoxy resins contained in the resin composition. 
     
     
         27 . The prepreg according to  claim 20 , which further comprises component (E): a thermoplastic resin. 
     
     
         28 . The prepreg according to  claim 27 , wherein the component (E) is contained in an amount of 1 part by mass or more and 15 parts by mass or less with respect to 100 parts by mass of a total of all epoxy resins contained in the resin composition. 
     
     
         29 . The prepreg according to  claim 20 , wherein the component (d1) is the dicyandiamide. 
     
     
         30 . The prepreg according to  claim 20 , wherein the component (d1) is the urea. 
     
     
         31 . The prepreg according to  claim 20 , wherein the component (d1) is the imidazole. 
     
     
         32 . The prepreg according to  claim 20 , wherein the reinforcing fibers comprise a carbon fiber. 
     
     
         33 . A fiber-reinforced plastic molded article comprising:
 a matrix resin having a sea-island structure formed from a bisphenol epoxy resin and a (meth)acrylate; and   carbon fibers,   wherein the fiber-reinforced plastic molded article has a flexural strength of 1800 MPa or more, a flexural modulus of 65 GPa or more, and an elongation at break of 8% or more.   
     
     
         34 . The fiber-reinforced plastic molded article according to  claim 33 , wherein the matrix resin comprises at least one component (d2) which is a radical polymerization initiator. 
     
     
         35 . The fiber-reinforced plastic molded article according to  claim 34 , wherein the component (d2) is at least one peroxide compound selected from the group consisting of methyl ethyl ketone peroxide, methyl cyclohexanone peroxide, methyl acetoacetate peroxide, acetylacetone peroxide, 1,1-bis(t-butylperoxy)3,3,5-trimethylcyclohexane, 1,1-bis(t-hexylperoxy)cyclohexane, 1,1-bis(t-hexylperoxy)3,3,5-trimethylcyclohexane, 1,1-bis(t-butylperoxy)cyclohexane, 2,2-bis(4,4-di-t-hexylperoxycyclohexyl)propane, 1,1-bis(t-butylperoxy)cyclododecane, n-butyl 4,4-bis(t-butylperoxy)valerate, 2,2-bis(t-butylperoxy)butane, 1,1-bis(t-butylperoxy)-2-methylcyclohexane, t-butyl hydroperoxide, P-menthane hydroperoxide, 1,1,3,3-tetramethylbutyl hydroperoxide, t-hexyl hydroperoxide, dicumyl peroxide, 2,5-dimethyl-2,5-bis(t-butyl)peroxy)hexane, α,α′-bis(t-butylperoxy)diisopropylbenzene, t-butylcumyl peroxide, di-t-butyl peroxide, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexyne-3, isobutyryl peroxide, 3,5,5-trimethylhexanoyl peroxide, octanoyl peroxide, lauroyl peroxide, cinnamate peroxide, m-toluoyl peroxide, benzoyl peroxide, diisopropyl peroxydicarbonate, bis(4-t-butylcyclohexyl)peroxydicarbonate, di-3-methoxybutylperoxydicarbonate, di-2-ethylhexylperoxydicarbonate, di-sec-butylperoxydicarbonate, di(3-methyl-3-methoxybutyl)peroxydicarbonate, di(4-t-butylcyclohexyl)peroxydicarbonate, α,α′-bis(neodecanoylperoxy)diisopropylbenzene, cumylperoxyneodecanoate, 1,1,3,3-tetramethylbutylperoxyneodecanoate, 1-cyclohexyl-1-methylethylperoxyneodecanoate, t-hexylperoxyneodecanoate, t-butylperoxyneodecanoate, t-hexyperoxypivalate, t-butylperoxypivalate, 2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)hexane, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate, 1-cyclohexyl-1-methylperoxy-2-ethylhexanoate, t-hexylperoxy-2-ethylhexanoate, t-butylperoxy-2-ethyl hexanoate, t-butylperoxyisobutyrate, t-butylperoxymaleic acid, t-butylperoxylaurate, t-butylperoxy-3,5,5-trimethylhexanoate, t-hexylperoxyisopropyl monocarbonate, t-butylperoxyisopropyl monocarbonate, t-butylperoxy-2-ethylhexyl monocarbonate, 2,5-dimethyl-2,5-bis(benzoylperoxy)hexane, t-butylperoxyacetate, t-hexylperoxybenzoate, t-butylperoxy-m-toluoylbenzoate, t-butylperoxybenzoate, bis(t-butylperoxy)isophthalate, t-butylperoxyallyl monocarbonate, 3,3′,4,4′-tetra(t-butylperoxycarbonyl)benzophenone, di-t-hexyl peroxide, and diisopropylbenzene hydroperoxide. 
     
     
         36 . A resin composition comprising a bisphenol epoxy resin and components (C), (D) and (H) below:
 component (C): a bi- or higher-functional (meth)acrylate compound,   component (D): a curing agent, and   component (H): an oxazolidone epoxy resin.   
     
     
         37 . The resin composition according to  claim 36 , wherein the bisphenol epoxy resin comprises component (A) below:
 component (A): a bisphenol epoxy resin with a softening point of 80° C. or more.   
     
     
         38 . The resin composition according to  claim 36 , wherein the component (D) comprises at least one component (d1) selected from the group consisting of a dicyandiamide, a urea, an imidazole, and an aromatic amine, and at least one component (d2) which is a radical polymerization initiator.