Epoxy and Epoxy-Hybrid Nano-Particle Resins for Carbon-Fiber Ship Structures By Ambient VARTM Process

The Navy has used vinyl ester resin as the matrix material for manufacturing large scale composite ship structures. However, the Navy is now using carbon fiber as the reinforcement, which means the use of vinyl ester as the matrix system is less appealing. When carbon fiber and vinyl ester resin are combined, lower interfacial properties occur. Also, vinyl ester systems have high-cure shrinkage. ZellComp proposes an epoxy resin that solves the problem of carbon fiber being able to achieve stiffness in the composite. Moreover, this epoxy resin overcomes inherent problems such as a high, as-cured glass transition temperature (Tg) and low viscosity. ZellComp will assess three technologies separately and in combination to achieve a tough, halogenated, fire-retardant epoxy.BENEFITS: ZellComp envisions great potential for FRP composites as an improvement over decks made with conventional materials such as steel and concrete. As part of our business strategy, ZellComp is exploring a subcategory of marine environment structures, where a design comprised of CFRP composites is a better solution. For these weight-critical applications, ZellComp proposes development of a resin suitable for low-cost composite fabrication processes such as VARTM that are capable of producing large structural decks efficiently. The goal is a tough, low-viscosity, ambient-cured epoxy resin that is fire-resistant and compatible with carbon fiber. Our vision of resin needs for ZellComp’s target market for marine structures matches the Navy’s needs as outlined in N06-T040. ZellComp is discussing collaborative efforts with major defense contractors. Outside ZellComp’s market domain in FRP composite structural decking, we see other opportunities for the developed resin system. We plan to partner with a supplier to market this resin system under a license agreement to other composite applications outside of decking. Similar resin needs exist in composites for aerospace components.