US 12,006,430 B2
Fire-retardant resins and composite materials
Laura-Jane Slade, Ryde (GB); Paul John Spencer, Southampton (GB); and Amy Alexandra Ferris, Cowes (GB)
Assigned to Gurit (UK) Ltd., Hampshire (GB)
Appl. No. 17/261,892
Filed by Gurit (UK) Ltd., Newport (GB)
PCT Filed Aug. 2, 2019, PCT No. PCT/EP2019/070923
§ 371(c)(1), (2) Date Jan. 21, 2021,
PCT Pub. No. WO2020/025806, PCT Pub. Date Feb. 6, 2020.
Claims priority of application No. 1812680 (GB), filed on Aug. 3, 2018.
Prior Publication US 2021/0284834 A1, Sep. 16, 2021
Int. Cl. C08J 5/24 (2006.01); B32B 27/38 (2006.01); C08G 59/24 (2006.01); C08G 59/36 (2006.01); C08G 59/38 (2006.01); C08K 3/34 (2006.01); C08K 3/36 (2006.01); C08K 3/38 (2006.01); C08K 3/40 (2006.01); C08K 5/19 (2006.01); C08K 5/21 (2006.01); C08K 5/315 (2006.01); C08K 5/3445 (2006.01); C08K 5/3492 (2006.01); C08K 5/5313 (2006.01); C08K 5/5357 (2006.01); C08L 63/00 (2006.01); C08L 63/02 (2006.01); C08L 63/04 (2006.01); C09J 7/35 (2018.01)
CPC C08L 63/04 (2013.01) [C08G 59/245 (2013.01); C08G 59/36 (2013.01); C08G 59/38 (2013.01); C08J 5/243 (2021.05); C08J 5/244 (2021.05); C08J 5/249 (2021.05); C08K 3/346 (2013.01); C08K 3/36 (2013.01); C08K 3/38 (2013.01); C08K 3/40 (2013.01); C08K 5/19 (2013.01); C08K 5/21 (2013.01); C08K 5/3155 (2013.01); C08K 5/3445 (2013.01); C08K 5/34922 (2013.01); C08K 5/5313 (2013.01); C08K 5/5357 (2013.01); C09J 7/35 (2018.01); C08K 2003/387 (2013.01); C08L 2201/02 (2013.01); C08L 2205/025 (2013.01); C08L 2205/035 (2013.01); C08L 2312/00 (2013.01); C09J 2463/00 (2013.01)] 28 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 which is solid at 20° C., and (ii) at least one second non-halogenated multifunctional epoxide-containing resin which has an epoxide functionality of less than or equal to 2 and which is liquid at 20° C.;
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, wherein the second fire retardant additive comprises or consists of ammonium polyphosphate and the ammonium polyphosphate of the second fire retardant additive is present in a concentration of from 27 to 32.5 wt % based on the weight of the epoxide resin, 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, 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.