WO1999045061A1

WO1999045061A1 - Halogen-free flame resistant composite

Info

Publication number: WO1999045061A1
Application number: PCT/DE1999/000361
Authority: WO
Inventors: Winfried Plundrich; Ernst Wipfelder
Original assignee: Siemens Aktiengesellschaft
Priority date: 1998-03-04
Filing date: 1999-02-10
Publication date: 1999-09-10
Also published as: AU3023299A; EP1060210A1

Abstract

The invention relates to a halogen-free flame resistant composite comprising a fibrous material and/or a woven material which is impregnated and hardened with a resin matrix. The resin matrix based on an epoxide/anhydride reactive resin is additionally made flame resistant with reactively inserting phosphorous compounds based on acid derivatives. The composite is suited as a light material for use in vehicle manufacturing, for example, for rail vehicles, assembly of motor vehicles and for ship and aircraft components.

Description

1 description

Halogen free flame retardant composite.

Composite materials based on epoxy resins and inorganic or organic reinforcement materials have successfully replaced conventional materials in many areas of technology and everyday life on the one hand because of their relatively simple and safe processing and on the other hand because of the good mechanical and chemical property values that can be achieved with them.

The so-called RTM technology (resin transfer molding) has proven itself in the production of large-area, customer-specific composite materials. A reinforcing material, e.g. a glass fiber fabric is placed in a mold, which is then filled with resin. If necessary, the process is supported by pressure and / or vacuum. It can be used to manufacture large-area parts such as those used for the lightweight construction of aircraft, ships and other vehicle components, as well as housings and construction materials in the electrical and construction industries.

Among other things, both epoxy /? Vmin and epoxy / anhydride systems are used for RTM technology. Epoxy / .Amin systems have the advantage that they can be cast and hardened at room temperature. In general, however, they have to be post-cured thermally in order to be fully cured. Epoxy / anhydride systems can also be processed at room temperature, but a slightly elevated temperature, e.g. B. 60 ° C, required. For widespread use, especially for vehicle components, however, such composite materials must meet the strict requirements with regard to flame resistance.

The fire specification applicable to plastics in rail vehicle construction is described in DIN 5510. For example 2 W is required in the S4 classification that the plastic is extinguished within 3 seconds after 3 mm of flame exposure without dripping, the diameter of the fire stain is <20 cm and, in addition, the integral smoke density does not exceed 50%.

The use of known flame retardants, such as. B. brominated resin components are extremely problematic because they split off large amounts of highly corrosive bromine-containing gases in the event of a disturbance, ie in the event of a fire or charring. In addition, they can form polybrominated dibenzo-dioxes and dibenzofurans during decomposition, which have a high toxicological-ecological-toxicological risk potential. Other flame retardants, such as antimony trioxide, are also unsuitable because they are on the list of carcinogenic chemicals.

Epoxy / amine or epoxy / anhydride systems and plastic systems based on unsaturated polyesters which are flame-retardant using aluminum hydroxide are known.

The high filler content required has a disadvantageous effect on the processability of the reaction resin and the mechanical strength of the composite material. This measure also removes the advantage of the low density of composite materials.

Patent applications WO96 / 23018 and DE-A 195 06 010 describe flame-retardant epoxy / anhydride casting resins, in which phosphorous and / or phosphonic acid anhydrides are added as additional reactive flame retardant components.

In the older German patent application 196 39 720.0, flame-retardant epoxy / amm systems for the lightweight construction of rail vehicles are mentioned which contain epoxy-functional phosphorus compounds. 3

The object of the present invention is to provide a reaction resin which is suitable for RTM technology, which is easy to process and which is flame-retardant, halogen-free, without the disadvantages observed with filled reaction resins and which, in combination with fibrous reinforcing agents, mechanical high-strength composite materials delivers.

Surprisingly, it has now been found that epoxy / anhydride systems and flame retardant components such as phosphine and / or phosphonic acid anhydrides with fibrous reinforcing agents result in high-strength, inherently flame-retardant composite materials which are ideally suited for processing by RTM technology.

Such thermoset materials show superior mechanical and chemical molding properties and offer high flame resistance even with small proportions of reactive phosphorus compounds.

Due to the large selection of starting components

Formulate composites with a wide range of properties and thus tailor-made for a multitude of applications.

The compositions according to the invention can advantageously be processed in the RTM process, since they have a long, adjustable service life even at elevated processing temperatures. An increased processing temperature also offers favorable flow and impregnation behavior due to the lowering of the viscosity.

By dispensing with additive flame retardants, e.g. Aluminum hydroxide can provide flame retardant low density composites.

The basic mechanical structure of the composite material according to the invention is a fiber or woven material which contains carbon, 4 glass, textile, plastic or natural fibers, such as jute fleece can include.

The resin matrix comprises an epoxy / carboxylic acid anhydride mixture, a reactive organic phosphorus compound based on an acid derivative, a reaction accelerator and processing aids such as defoamers, leveling agents and adhesion promoters. The reaction resin matrix based on the epoxy / anhydride system is almost freely selectable, with the proviso that the viscosity is sufficiently low for the RTM technique. However, this condition is met by a variety of epoxy / anhydride systems. For example, well suited aromatic and cycloaliphatic polyglycidyl ethers, such as bisphenol A or bisphenol F diglycidyl ether, hydrogenated bisphenol A or bisphenol F or diglycidyl ether, polyglycidyl ethers of phenol or cresol formaldehyde resins and cycloaliphatic glycidyl esters such as e.g. Hexahydrophthalic acid diglycidyl ester. Cycloaliphatic ring epoxidized resins such as e.g. 3,4-epoxycyclohexyl-methyl- (3,4-epoxy) cyclohexane carboxylate and bis (3,4-epoxycyclohexyl) adipate.

As viscosity-reducing epoxy components, aliphatic difunctional glycidyl ethers, such as ethylene glycol diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, neopentyl diglycidyl ether, polypropylene di-glycidyl ether, cyclopyalidyl ether, polytetcydalidyl ether, polytetcydidyl ether, polytetcahydrofuryldihydrofuran such as trimethylolpropane triglycidyl ether or monofunctional aromatic glycidyl ether, such as p-tert. Butyl glycidyl ether and o-cresyl glycidyl ether and also monofunctional aliphatic glycidyl ethers such as n-butyl glycidyl ether and 2-ethylhexylglycidyl ether are advantageously used.

Common, preferably liquid anhydrides based on di- and tetracarboxylic acids are used as the carboxylic acid anhydride. 5 Hexahydrophthalic anhydride, methylhexahydrophthalic anhydride, methyltetrahydrophthalic anhydride and methylenedomethylene tetrahydrophthalic anhydride are particularly suitable. In admixture with liquid anhydrides, succinic anhydride and phthalic anhydride as well as benzene

1,2,4,5-tetracarboxylic acid dianhydride, benzophenonetetracarbonic acid dianhydride and biphenyltetracarboxylic acid dianhydride can be used.

Organic derivatives of phosphoric acid, phosphinic acid, phosphonic acid and phosphine oxide are suitable as the reactive organic phosphorus compound.

Phosphonic acid anhydrides of the general structural formula are particularly advantageous

O

[- P - o-

R -]

and phosphinic anhydrides of the general structural formula

OO, ι _R II II ¹ ^κ ^ ^p - o- ^p

R ^ R

in which R and R ¹ independently of one another are an alkyl or alkenyl radical having 1 to 40 carbon atoms or a cycloaliphatic or an aryl radical and n is an integer.

To reduce the viscosity, the P-containing epoxy / anhydride system can also be admixed with low-viscosity glycidyl esters of phosphonic acid derivatives. Important representatives of this class of substances are, for example, methyl, propyl or phenylphosphonic acid diglycidyl esters. However, these last-mentioned P compounds have a relatively low phosphorus content compared to propanephosphonic acid anhydride, as can be seen from Table 1.

Table 1: Characteristic values for the P components

P components P content proportions of the P components of the components in the resin formulations

(theoretical) (%)

P = 3% P = 4% P = 5%

Phenylphosphone 11.4 26.3 35.1 43.9 acid diglycidyl ester

Methane phosphon 14.8 20.3 27.0 33.8

acid diglycidyl ester

Propanephosphone- 29.0 10.3 13.8 17.2

acid anhydride

The best flame retardant effect of composite materials according to the invention are found among the P-compounds with e.g. Propane phosphonic anhydride achieved, which can also be used in a relatively low concentration.

The aforementioned P-containing compounds harden together with the epoxy / anhydride system and are integrated into the resulting network of the reaction resin matrix. A particularly good integration into the resin matrix is a phosphorus compound, the integration of which can take place via at least two of the reactive groups mentioned. 7 The ratio of the epoxy function to the anhydride function, consisting of P-free anhydride and P-containing anhydride, is 1.0: 0.7 to 1.0: 1.0, preferably between 1.0: 0.9 and 1, 0: 1.0.

The reactivity of the reaction resin composition is not influenced by the phosphorus-containing compound in comparison to a phosphorus-free reaction resin composition. In addition, the reactivity of the entire reaction resin mass can be set using a freely selectable reaction accelerator.

Tertiary amines, e.g. Dimethylbenzylamine or tris-dimethylamino-methylphenol, organometallic complexes or imidazoles, e.g. B. 2, 4-ethylmethylimidazole, 1-methylimidazole or 1-position cyanoethylated imidazoles, such as l-cyanoethyl-2-phenylimidazole.

By selecting suitable accelerator systems and concentrations, it is possible to adjust the reactivity of the reactive resin compound so that a long service life, adapted to the RTM process, is obtained at 60 ° C and hardened at 60 ° C and demolded within 10 hours can be.

Figure 1 shows the isothermal viscosity curve of a P-containing epoxy / anhydride system at different temperatures. The mixture according to the invention shown has a P content of 2.5% by weight and an accelerator content of 1%. From the viscosity curve, e.g. derive a service life of> 3 hours at 60 ° C.

A sufficient service life, which is particularly advantageous in the production of large modules, as is advantageous, for example, for rail vehicle construction, is achieved with an accelerator proportion of 0.1 to 5.0 percent by weight, preferably less than 1.0 percent by weight. A composite material has advantageous usage properties, the resin matrix of which has a processing temperature between 20 and 60 ° C and a viscosity of less than 300 mPa at the processing temperature. s shows and which has a service life of at least one hour.

The composite material has the further advantage that the flame retardant by means of phosphor modification of the organic resin matrix is harmless to the environment, since no toxic substances are released in the event of fire or through charring. Due to the chemical incorporation of the phosphorus compound in the hardened resin matrix and thus in the composite material, the phosphorus compound is also built into it in an aging-resistant manner against sweating, washing out or other erosion.

Since the flame retardant properties of the composite materials according to the invention are obtained without additional, specifically heavier, inorganic additives, they also have a relatively low specific weight, so that there is preferred use for vehicle construction, in which weight reduction brings decisive advantages.

Due to the good processability of the resin composition or the fiber or fabric material impregnated with the Harmatrix, a good filling of the casting mold is also achieved when producing the composite material, which creates smooth and clean surfaces in the composite material, which no longer require any surface treatment and with conventional paints are coverable. Good adhesion forms between the fiber-containing material and the resin matrix, which has a positive effect on the stability of the composite material. The good wetting of the fibers with the resin matrix and the good adhesion in the hardened state are responsible for the fact that the

Afterburning times after flame treatment of the composite material are only a few seconds. A composite material with sufficient flame retardancy is obtained if phosphorus contents of 2 to 5 percent by weight are set in the resin matrix. This phosphorus content can be adjusted with a relatively low proportion of phosphorus compound if it already has a high phosphorus content. As described in Table 1, phenylphosphonic acid diglycidyl ester has a phosphorus content of 11.4 weight percent, methanephosphonic acid diglycidyl ester of 14.8 weight percent and propanephosphonic acid anhydride of 29.0 weight percent. With these phosphorus contents of the phosphorus compound, for example, a phosphorus content of 3 percent m of the reaction resin matrix is obtained if the phosphorus compound m is added to the hard matrix in a proportion of 26.3, 20.3 and 10.3 percent by weight. In particular, the high phosphorus content of the phosphonic acid anhydride makes it possible to add a low proportion of phosphorus compound for adequate flame protection. This ensures that the otherwise practically freely selectable epoxy / anhydride system remains virtually unchanged in its chemical-physical properties and is not adversely affected. Due to the chemical incorporation of the phosphorus component in the hardened resin matrix, the phosphorus compound functions as an active hardener component and not as an unreactive additive, which could adversely affect the properties if the dosage is too high.

The low content of phosphorus compound is also positive for the potential hydrolysis sensitivity of the hardened resin matrix. The composite materials according to the invention show only a low water absorption of less than 0.5 percent, the typical value is 0.2 percent.

A composite material, which is particularly suitable for the production of large-area self-supporting parts, in particular for vehicle construction, is made by additionally installing a 10 layer of a lightweight material, in particular a foam layer in a then three-layer composite material. For its manufacture, a lightweight construction material, for example a foam core, is given a shape on both sides with several layers of fibrous fabric, pressed and impregnated with resin. Complete filling of the mold can be achieved by filling the resin matrix under pressure and, if necessary, evacuating the mold. This clean, complete filling of the mold is supported by the low viscosity and the long service life of the reactive resin compound.

A suitable foam for a corresponding composite material according to the invention is obtained from polyurethane or PVC. Also honeycomb structures with fiber-reinforced reactive resin application on both sides can be easily constructed.

A casting mold is preferably used which, after being filled with the resin composition, can be heated to a preheating temperature of at least 60 ° C. At this pre-curing temperature, the resin mass cures to such an extent that the hardened composite material can easily be removed from the mold and cured at a higher temperature. In general, a pre-curing time of approx. 10 hours is sufficient.

A composite material according to the invention comprises at least one fiber-containing material which is impregnated and hardened with a resin matrix. Processing using the RTM process in the closed mold makes it possible to add other layers of it to the fiber in addition to the fiber-containing material

Install composite material. In addition to the foams already mentioned, these can also be other layers. A composite material with a foam is particularly suitable for vehicle construction because of the relatively low weight and the good mechanical and heat-insulating properties obtained at the same time. For example, 11 Manufacture modules for cabins of rail vehicles from this material in a simple manner.

The invention is explained in more detail below with the aid of exemplary embodiments and the associated two further figures.

Figure 1 shows the isothermal viscosity curve of a P-containing epoxy / anhydride system

Figures 2 and 3 show a first (two-component) and a second (three-component) composite material in a schematic cross section

example 1

435.2 parts by weight of bisphenol-F-diglycidyl ether (Rutapox 0158, Bakelite), 108.8 parts by weight of epoxy-phenol novolak (DEN 438, Dow Corning), 4.9 parts by weight of adhesion promoter (A187, Wacker), 1.0 part by weight of defoamer ( A500, Byk) are mixed with 318.4 parts by weight of methyl hexahydrophthalic anhydride (Harter M, Hüls), 120.8 parts by weight of the phosphorus component propane-phosphonic acid anhydride and 10.9 parts by weight of accelerator 1-methyl imidazole at 60 - 70 ° C, degassed and then in a 4th mm thick plate casting mold, which is provided with 12 layers of glass fabric (390 g / m ² ) and 1 layer of glass fleece, filled under a slight vacuum of 0.5 mbar.

This reaction resin matrix, which has a phosphorus content of only 3.5% phosphorus, has a service life of> 3 hours at 60 ° C. The viscosity is 200 mPas.

After curing for 10 h at 60 ° C, the mold is removed. A dimensionally stable, tack-free plate is obtained, which is then post-baked at 120 ° C. for 2 hours. Figure 1 shows the plate 1 in schematic cross section. In general, a high proportion of fibrous material 2 is sought in the composite material, which can reach up to 60 percent by volume. The composite material achieves a higher mechanical strength with a higher proportion of fiber-containing material, which is only shown schematically here. The hardened resin matrix is denoted by 3 in the figure. In addition to the glass fleece used in the example, carbon, textile or aramid fibers are also suitable for high strengths.

The cast plate, which has a glass fiber content of 60% by mass, shows a glass transition temperature of 82 ° C after hardening and a glass transition temperature of 97 ° C after complete hardening. The surfaces are smooth and homogeneous and can be coated well with varnish without additional post-treatment.

Test specimens produced from this have high mechanical strengths, e.g. E-modulus> 23 GPa (bending test according to DIN 53452) and a low water absorption according to DIN 53495 with 0.20% after 3 days at 23 ° C.

The fire behavior for plastics in rail vehicle construction is fulfilled according to DIN 5510-2, both with the flame protection specification according to classification S4 (afterburning time 5 sec, damage size of the flame 13 cm) and with the flue gas density according to classification SR 2 (45% light attenuation - integral over the whole Test duration).

Example 2

348.8 parts by weight of cycloaliphatic epoxy (CY 179, Ciba Geigy), 149.5 parts by weight of reactive thinner butanediol diglycidyl ether (DY026, Ciba Geigy), 4.7 parts by weight of adhesion promoter 3-glycidyloxypropyltrimethoxysilane (Glymo, Hüls), 0.9 parts by weight of defoamer , Byk) with 311.9 13 parts by weight of methylhexahydrophthalic anhydride (Harter M, Hüls), 173.9 parts by weight of propanephosphonic anhydride and 10.2 parts by weight of accelerator 1-methylimidazole mixed and degassed at room temperature. This reaction resin mixture has a viscosity of 280 mPas at 25 ° C; the service life is> 4 hours.

This reaction resin matrix is used to produce a 58 mm thick composite material at room temperature using RTM technology, consisting of a 50 mm thick solid polyurethane foam material (arranged in the center) and with 12 layers of glass fabric on each side. After curing for 3 hours at 80 ° C, the mold can be removed.

After curing (3 h at 120 ° C) a glass transition temperature of 92 ° C is obtained. The thermoset material produced, which results in a very good bond between the polyurethane foam core and the glass fiber-filled epoxy resin layer, fulfills the requirements as a material, e.g. for the use of car body modules for rail vehicles, with regard to

Flame retardant specification, mechanical, electrical and chemical molding properties. With this e.g. a vehicle body for a rail vehicle can be produced without additional support elements.

FIG. 2 generally shows a three-layer composite material in a schematic cross section through the layers with the foam layer 4 and the hardened reaction resin matrix with the fiber material 2.

Example 3

In a vacuum-tight casting mold heated to 40 ° C, in which 12 layers of glass fabric (390 g / m ² , 0.45 mm) and 1 layer of glass fleece are inserted, a plate test piece measuring 500 mm x 190 mm x 5 mm is produced. The casting is carried out in a vacuum (approx. 10 mbar) with a reaction heated to 40 ° C. 14 resin matrix, consisting of 146.9 parts by weight of bisphenol-F-diglycidyl ether (Rutapox 0158, Bakelite), 36.7 parts by weight of epoxy-phenol novolak (DEN 438, Dow Corning), 60.4 parts by weight of the epoxy-containing phosphorus component phenylphosphonic acid diglycidyl ester (max ), 55.9 parts by weight of the anhydride-containing phosphorus component propanephosphonic anhydride, 153.4 parts by weight of methylhexahydrophthalic anhydride (Hüls), 2.1 parts by weight of 3-glycidyloxypropyltrimethoxysilane (Hüls), 0.5 parts by weight of defoamer (A 500, Byk) and 4.6 Parts by weight of 1-methylimidazole (Fluka). The phosphorus content is 5.0%.

This reaction resin matrix has a low viscosity of 520 mPas at 25 ° C, 220 mPas at 40 ° C and 140 mPas at 60 ° C. The service life at 40 ° C is> 6 h. After 4 hours of hardening at 80 ° C, an easily demoldable, solid plate body with a glass transition temperature of 81 ° C is obtained. Complete curing with a glass transition temperature of 91 ° C is achieved after 4 h at 100 ° C. Flame-retardant, glass fiber-reinforced molded materials produced in this way also meet the fire behavior according to DIN 5510-2.

Example 4

To further reduce the smoke density, 50.0 parts by weight of dried calcium carbonate (type CCP, average particle diameter 0.9 μm, from Schafer) are added to the reaction resin solution (reaction resin matrix) described in Example 1. Sedimentation of the filler cannot be determined during processing. Likewise, the fine-grain filler shows no impairment when pouring. The service life of> 3 h is retained. The filler of 5% increases the viscosity only slightly.

Fiber-reinforced plate test bodies are also produced as described in Example 1. The flame protection specification according to DIN 5510-2 is achieved with a 15 burning time of 0 sec and a damage height of 14 cm (classification S4) and an integral smoke density according to classification SR 2 (light attenuation 35%).

Example 5

240.8 parts by weight of bisphenol-F-diglycidyl ether (Rütapox 0158, Bakelite), 60.2 parts by weight of epoxy-phenol novolak (DEN 438, Dow Corning), 2.8 parts by weight of adhesion promoter (A187, Wacker), 0.5 parts by weight of defoamer ( A500, Byk) are mixed with 176.2 parts by weight of methylhexahydrophthalic anhydride (Hardener M, Hüls), 66.8 parts by weight of the phosphorus component propanephosphonic anhydride and 2.7 parts by weight of accelerator 1-methylimidazole at 60 - 70 ° C, degassed and then in a 3rd mm thick plate mold, which is provided with 8 layers of carbon fiber, filled under a vacuum of 30 mbar.

This pourable reactive resin matrix, which is very easy to process at 80 ° C, has a low viscosity of 120 mPas. The service life at 80 ° C is> 1 hour, at 70 ° C> 3 hours. The phosphorus content is 3.5%.

The curing takes place for 3 hours at 100 ° (Tg = 84 ° C) or 1 hour at 120 ° C. After removal from the mold, a dimensionally stable, tack-free plate is obtained, which is then cured for a further 3 hours at 150 ° C. (Tg = 100 ° C.) or for 1 hour at 160 ° C.

The surface of the plate produced, whose carbon fiber content is 60% by volume, is smooth and shows a homogeneous appearance. It can be coated with varnish without additional post-treatment.

Test specimens produced from this have high mechanical strengths, for example elastic modulus> 25 GPa (bending test according to DIN 53452) and low water absorption according to DIN 53495 with 0.18% after 3 days at 23 ° C. 16

The plate produced fulfills the fire behavior for plastics in rail vehicle construction according to DIN 5510-2. The flame protection specification is obtained according to classification S 4, with an afterburn time of 0 sec and a flame damage size of 12 cm and a specification for smoke density according to classification SR 2 with an integral light attenuation of only 24%.

Claims

17 claims

1. Halogen-free, flame-retardant composite material comprising a fiber and / or fabric material that is impregnated and hardened with a resin matrix, the resin matrix being composed of at least the following components

A) an aliphatic and / or cycloaliphatic and / or aromatic epoxy resin, preferably a low-viscosity epoxy resin,

B) a carboxylic acid anhydride as a hardener, preferably a liquid carboxylic acid anhydride C) one or more phosphorus compounds based on acid derivatives, D) a reaction accelerator used in epoxy resin chemistry, such as e.g. a tertiary min and / or imidazole or organometallic complex E) one or more processing aids, such as filler, defoamer, flow aid, adhesion promoter.

2. The composite material according to claim 1, having a phosphorus content of 0.5 to 5 percent by weight, based on the resin matrix.

3. Composite material according to one of claims 1 to 2, wherein the phosphorus compound C) is selected from a phosphine and / or phosphonic acid anhydride.

4. Composite material according to one of claims 1 to 2, in which the phosphorus compound C) is selected from the acidic ester of a di- or tetracarboxylic acid anhydride with a hydroxy-functional phosphonic or phosphonic acid compound.

5. Composite material according to one of claims 1 to 2, in which the phosphorus compound C) is selected from

Glycidyl esters of phosphonic acids. 6. The composite material according to one of claims 1 to 2, in which the phosphorus compound C) is selected from mixtures according to claims 3 to 5.

7. The composite material according to one of claims 1 to 6, in which the ratio of the epoxy resin function to the anhydride function is 1.0: 0.7 to 1.0: 1.0 and preferably between 1.0: 0.9 and 1.0: 1.0 is.

8. The composite material according to claims 1 to 7, in which the reactivity can be adjusted by selecting and concentrating the accelerator (component D) so that on the one hand the hardening at low temperature, e.g. 60 ° C and on the other hand the resin mixture has a long service life and e.g. 80 ° C can be reached.

9. The composite material according to claims 1 to 8, in which component E) is selected from quartz material, aluminum hydroxide, calcium carbonate, graphite and / or carbon black.

10. Composite materials according to one of claims 1 to 9, with a fiber and / or fabric material based on inorganic or organic reinforcing materials in the form of fibers, nonwovens or fabrics, in particular glass, carbon, textile or natural fibers.

11. Composite materials according to one of claims 1 to 10, which comprise on both sides of a foam layer and in a firm bond with it in each case several layers of a fiber-containing fabric impregnated with a resin matrix.

12. A method for producing a composite material according to one of claims 1 to 11,

- In which several layers of a fibrous fabric are laid out in a closed mold 19

- In which both the epoxy resin mixture and the mold can be brought to room temperature or elevated temperature

- in which components A) to E) are mixed and then poured into the 60 ° C warm mold using an injection process at the processing temperature without bubbles

- at which the casting mold is brought to a hardening temperature of at least 60 ° C and the epoxy resin mixture is thereby hardened

- in which the hardened composite material is removed from the mold and cured at elevated temperature, or in which the composite material in the casting mold is cured at elevated temperature and then removed from the mold.

13. Use of a composite material according to one of claims 1 to 11 as a light material in vehicle construction, e.g. for rail vehicles, superstructures of motor vehicles and ship and aircraft components.