Method for producing a fiber-reinforced composite material plate
A method for producing a fiber-reinforced composite material plate by heating and pressurizing a prepreg for a molding time of 15 minutes or less, at a molding temperature of at least 120° C. and a molding pressure of at least 10 kg/cm 2 . The prepreg is prepared from a reinforcing fiber and an epoxy resin composition. The epoxy resin composition features: an epoxy resin; an amine compound having at least one sulfur atom in the molecule thereof and/or a reaction product of the epoxy resin and the amine compound having at least one sulfur atom in the molecule thereof; a urea compound; and a dicyandiamide. The contents of the sulfur atom and the urea compound in the epoxy resin composition are respectively 0.2 to 7% by mass and 1 to 15% by mass.
1. A method for producing a fiber-reinforced composite material plate, comprising:
preparing a prepreg comprising a reinforced fiber and an epoxy resin composition; and
heating and pressurizing the prepreg for a molding time of 15 minutes or less, at a molding temperature of at least 120° C. and a molding pressure of at least 10 kg/cm 2 , to mold the prepreg into the fiber-reinforced composite material plate;
wherein the epoxy resin composition, comprises:
a component A;
a component B;
a component C; and
a component D;
wherein:
a content of a sulfur atom in the composition is from 0.2 to 7% by mass;
a content of component C in the composition is from 1 to 15% by mass;
the component A comprises an epoxy resin;
the component B comprises an amine compound having at least one sulfur atom in a molecule thereof (component B-1) and/or a reaction product of the epoxy resin and the amine compound having at least one sulfur atom in the molecule thereof (component B-2);
the component C comprises a urea compound; and
the component D comprises a dicyandiamide.
2. The method according to claim 1 , wherein the component A comprises at least one epoxy resin selected from the group consisting of a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a bisphenol S type epoxy resin, a phenol novolac type epoxy resin, and a cresol novolac type epoxy resin.
3. The method according to claim 1 , wherein a Gel time of the epoxy resin composition at 130° C. is equal to or less than 200 seconds.
4. The method according to claim 1 , 2 or 3 , wherein the component C comprises particles having an average particle diameter equal to or less than 150 μm.
5. The method according to claim 1 , wherein the epoxy resin composition is obtained by:
mixing component A and component B-1; and
further mixing component C and component D with component A and component B-1to obtain the epoxy resin composition.
6. The method according to claim 5 , wherein, when the resin composition is obtained by mixing component A and component B-1, component B-2 is formed and included in the resin composition.
7. The method according to claim 1 , wherein the prepreg is prepared by impregnating the epoxy resin in the reinforced fiber.
8. The method according to claim 1 , wherein the reinforced fiber is a carbon fiber.
9. The method according to claim 1 , wherein the reinforced fiber is unidirectional or woven.
10. The method according to claim 1 , wherein the prepreg consists of the reinforced fiber and the epoxy resin composition.