Urethane Methacrylate Prepreg Resin Composition Room Temperature Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current prepreg resin compositions using epoxy resins face challenges in workability and molding properties at room temperature, requiring refrigerated storage and insufficient for forming molded articles with excellent heat resistance and interlayer shear strength.
Innovation Solution
A prepreg resin composition containing a specific urethane (meth)acrylate reaction product of polyisocyanate, polyol, and hydroxy alkyl (meth)acrylate, combined with a polymerization initiator and reinforcing fibers, which improves workability and molding properties, enabling the formation of molded articles with enhanced heat resistance and interlayer shear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If epoxy resin is used for prepreg, then stability at room temperature is achieved, but workability and molding properties deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by using urethane (meth)acrylate instead of epoxy resin, and by controlling the gel fraction within 30-70 wt%. This parameter change maintains room temperature stability while improving workability and molding properties, as the urethane (meth)acrylate system allows for better processing characteristics and mold filling behavior.
Solution Approach 2:
The patent creates a composite material system combining urethane (meth)acrylate with specific gel fraction characteristics. This composite approach integrates the stability benefits of crosslinked urethane structures with the processability advantages of controlled gel fractions, achieving both room temperature stability and improved workability simultaneously.
2Productivity
If urethane (meth)acrylate compound is used to achieve high productivity, then productivity is improved, but workability and molding properties become insufficient
Solution Approach 1:
The patent optimizes the gel fraction parameter to 30-70 wt%, which fundamentally changes the material's flow and processing characteristics. This parameter optimization enables the high-productivity urethane (meth)acrylate system to achieve both rapid curing and excellent workability, as the controlled gel fraction prevents premature setting while maintaining high reactivity.
3Stability of the object's composition
If prepreg is cured at room temperature, then stability is maintained, but storage conditions become problematic
Solution Approach 1:
The patent changes the curing temperature parameter from room temperature to elevated temperatures (typically 80-150°C). This parameter change allows the material to remain stable during storage at ambient conditions while enabling complete curing and optimal performance through thermal activation, eliminating the need for refrigerated storage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed composition allows for the production of molded articles with superior heat resistance and interlayer shear strength, suitable for various structural applications, including automotive, aerospace, and construction materials, while maintaining stability at room temperature.
Implementation Method 1
a urethane (meth)acrylate (A) that is a reaction product of polyisocyanate (a1), polyol (a2), and hydroxy alkyl (meth)acrylate (a3)
Implementation Method 2
a polymerization initiator (B), as an essential component
Data Source
AI summary
Provided is a prepeg resin composition, containing: a urethane (meth)acrylate (A) that is a reaction product of polyisocyanate (a1), polyol (a2), and hydroxy alkyl (meth)acrylate (a3); and a polymerization initiator (B), as an essential component, in which the polyisocyanate (a1) is at least one polyisocyanate selected from 2,4′-diphenyl methane diisocyanate, 4,4′-diphenyl methane diisocyanate, a carbodiimide modified product of 4,4′-diphenyl methane diisocyanate, and polymethylene polyphenyl polyisocyanate, and the polyol (a2) has an aromatic-ring and an oxyalkylene structure. The prepreg resin composition of the invention is excellent in workability and molding properties, and is capable of forming a molded article excellent in various physical properties such as external appearance and heat resistance, and thus, can be preferably used in a prepreg and a molded article thereof.