Dual polymer bonding of thermoplastic composite structures

This paper describes a process that facilitates fusion bonding of thermoplastic composite components without the need for complex fixtures and without disrupting the fiber alignment in the component laminates. The dual polymer bonding process, Thermabond, requires that an interlayer polymer be fused to the surface of each laminate prior to bonding. The characteristics of the interlayer polymer allow for joining of the components at a temperature below the softening/melting point of the reinforced polymer in the composite laminates. This leads to significant processing advantages without significant loss in mechanical performance. Discussions of resin compatibility, the effect of process conditions on mechanical performance, and the application of the APC-2/PEI Thermabond system to various structural components are included.     

Dynamic mechanical response of a thermoplastic sheet molding compound-glass fiber composite

The dynamic mechanical properties of nylon 6/continuous glass fiber composites at four levels of fiber volume content were studied between -180 and 130°C using a free resonance torsion pendulum. The composites were produced by anionically polymerizing caprolactam monomer within a swirl type glass fiber mat using a vacuum injection technique. In addition to the expected strong dependence of shear storage modulus on fiber volume content, the glass transition temperature of the nylon 6 was observed to increase slightly and the mechanical damping decrease with fiber volume fraction. Introduction of about 7 weight percent water (i.e., equilibrium hygroscopic state) into the composite led to a considerable broadening of the transition peaks and a much lower plasticizing action of water in the composite relative to the pure nylon 6 matrix.     

Specific volume of molten thermoplastic polymer composite at high pressure

The specific volume of thermoplastic polymers and composites with glass fiber have been measured at high pressure, up to 2000 kg/cm², in the molten state by a dilatometer. The specific volume and thermal expansion coefficient of the melts increase with increasing temperature at a constant pressure at a constant temperature. The data of specific volume of molten polymers were satisfactorily fitted to an empirical equation of state based on the Tait equation. Furthermore, it is found that the data of specific volume of molten composites were suitably fitted by an additive rule of Tait equation from the volume fractions of specific volume of polymers and the glass fiber in composites. The thermal expansion coefficients of molten polymers and composites are approach to the derivative values of the Tait equation, and the additive Tait equation, respectively.     

A method of forming composite structures using in situ-formed liquid crystal polymer fibers in a thermoplastic matrix

A new high speed and potentially economical method of creating a composite material and structures therefrom is tested. The method consists of spinning composite fibers from a melt blend of a thermoplastic with a liquid crystal polymer (LCP). Discontinuous fibrils of the LCP are formed in situ during the spinning process. These composite fibers are aligned and placed in a mold and heated to melt the thermoplastic matrix, but not the fibrils. A finished composite structure reinforced by the LCP fibrils is obtained when the thermoplastic phase is consequently consolidated. Our experiments show the proposed process is reasonable for an easily processed polystyrene matrix. High modulus fibrils with essentially infinite L/D ratios are readily produced in the extrusion process using 40 wt% of a wholly aromatic poly(ester-co-amide) LCP from Celanese. The integrity and alignment of the LCP fibrils is retained in the molding step. Mechanical tests show that the fibers produced by high shear rate processing have a stiffness approaching 23 GPa and match an axial rule-of-mixtures theory. The use of polystyrene resulted in brittleness. Molded composite plates exhibit slightly lower stiffness and significantly lower strength than individual fibers.     

Mechanical properties of carbon nanotube/carbon fiber reinforced thermoplastic polymer composite

Carbon nanotube (CNT)/carbon fiber (CF) hybrid fiber was fabricated by sizing unsized CF tow with a sizing agent containing CNT. The hybrid fiber was used to reinforce a thermoplastic polymer to prepare multiscale composite. The mechanical properties of the multiscale composite were characterized. Compared with the base composite (traditional commercial CF), the multiscale composite reinforced by the CNT/CF hybrid fiber shows increases in interlaminar shear strength (ILSS) and impact toughness. Laminate containing CNTs showed a 115.4% increase in ILSS and 27.0% increase in impact toughness. The reinforcing mechanism was also discussed by observing the impact fracture morphology. POLYM. COMPOS., 38:2001–2008, 2017. © 2015 Society of Plastics Engineers     

Dynamic response and safety assessment of a batch process on cooling breakdown

Cooling breakdown in highly exothermic reaction processes may lead to runaway. The sensitivity and the safety assessment of a batch process on cooling breakdown are studied. The dependence of the minimum cooling time and the maximum allowable time of cooling breakdown for safe operation on the process parameters is investigated.     

Isomerization behavior of aromatic azo chromophores bound to semicrystalline polymer films

The cis–trans isomerization of azo chromophores covalently bound to semicrystalline polymer films was investigated. Various azo chromophores were introduced onto the functionalized semicrystalline polymer films by a chemical transformation reaction and their isomerization behavior was investigated by UV‐visible spectroscopy and a contact‐angle goniometer. The thermal Z → E isomerization rate of the azo moiety covalently bound to low‐density polyethylene (LDPE) and polypropylene (PP) films was determined. The rate of thermal isomerization was also compared between amorphous and semicrystalline polymer films bearing azo chromophores. The effect of the intramolecular steric factor and the nature of chromophores was studied on the thermal isomerization rate of the polymer films. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2923–2928, 2001     

热塑性复合材料中的高分子吸附包覆现象

通过对三相复合材料PP/GF/PA66、PP/GF/PET、PP/GB/PA66、PP/GB/PET以及PP/PA66/PET的力学性能和微观形貌的比较分析,研究了三相复合材料的界面吸附现象。实验结果表明,高分子的极性在多相体系的界面形成过程起着非常重要的作用。在熔融加工时,极性高分子能优先吸附包覆在极性无机填料或极性高分子表面;三相体系中的极性优先吸附包覆作用改善了无机填料和高分子基体之间的界面结合,使材料的力学性能优于不存在优先吸附作用的三相体系的力学性能。此外,通过比较分析复合材料组分之间的界面张力,从界面能的角度解释了多相复合材料中的优先吸附包覆现象。     

Development of a multimicroinjection molding system for thermoplastic polymer

A novel concept of microinjection molding system was designed and presented. The system was designed as a multimicroinjection module, which is matched with a vertical injection molding machine (IMM) and can be applied on commercial IMMs. A planetary gear pump was integrated in this system to complete the multi microinjection molding (MμIM). The module is fixed between the stationary platen and the mold of IMM. The plasticizing unit of the IMM provides the melt and initial pressure for the multi microinjection molding system. With this system, a commercial IMM could be upgraded to a precise microinjection machine and has the capability of precise metering for the microinjection molding. Melt flowing behavior was predicted through the 3D injection molding simulation and experiments were carried out to testify the performance of the MμIM. The injection molding performance was evaluated and the results revealed that the MμIM system could effectively realize the microinjection molding. POLYM. ENG. SCI., 2012. © 2012 Society of Plastics Engineers     

Morphology development of in situ compatibilized semicrystalline polymer blends in a co-rotating twin-screw extruder

This paper concerns the morphology development of in situ compatibilized semicrystalline polymer blends in a co-rotating, intermeshing twin-screw extruder, using polypropylene (PP) and polyamide 6 (PA-6) blends as model systems. The morphology of in situ compatibilized blends develops much faster that of mechanical ones. The size of the dispersed phase (PA-6) undergoes a 10⁴ fold reduction from a few millimeters to sub-micron during its phase transition from solid pellets to a viscoelastic fluid. The final morphology is reached as soon as the phase transition is completed, which usually requires only a small fraction of the screw length in a co-rotating twin screw extruder. Screw profiles and processing conditions (screw speed, throughput and barrel temperature) control the PA-6's melting location and/or rate, but do not have significant impact on the ultimate morphology and mechanical properties of in situ compatibilized blends. The finding that morphology of PP/PA-6 reactive blend develops rapidly makes it possible to produce compatibilized PP/PA-6 blends by the so-called one-step reactive extrusion. It integrates the traditionally separated free radical grafting of maleic anhydride onto PP and the compatibilization of PP/PA-6 into a single extrusion step.     

Design and processing of a thermoplastic composite reinforced wood structure

Reinforced wood structures retain the advantages of natural wood while they allow increased life and better performance. Wood reinforced with thermoset composites has been studied earlier. We for the first time develop a process and design methodology for a thermoplastic-reinforced wood structure. A wood floor structure was reinforced by the means of adhering a thin layer of consolidated thermoplastic composite. The process for consolidating commingled E-glass/polypropylene yarns and adhering the composite to wood was designed and tested. The time for preheating and consolidating the commingled thermoplastic yarns on top of wood was predicted analytically and compared with experimental results. An optimal design methodology for the wood/composite floor structure is also developed. Polym. Compos. 25:119–133, 2004. © 2004 Society of Plastics Engineers.     

Dissolution of semicrystalline polymer fibers: Numerical modeling and parametric analysis

The solvent processing of polymers is significantly constrained by polymer chain crystallinity. A phenomenological model is developed here that captures the phenomena governing the dissolution of semicrystalline polymers, for example, solvent penetration, transformation from crystalline to amorphous domains, specimen swelling, and polymer chain untangling. The model is validated for the case of cellulose fiber swelling and dissolution in an ionic liquid. A parametric sensitivity analysis is performed to assess the impact of decrystallization rate constant, disentanglement rate, concentration dependence of solvent diffusivity, disentanglement threshold, and thickness of external boundary layer on the swelling and dissolution of semicrystalline polymer fibers. The rate of dissolution after attaining maximum swelling is found to be mainly controlled by the polymer chain disentanglement rate. The insights obtained from this study would facilitate the design of efficient solvent systems and processing conditions for the dissolution of semicrystalline polymers such as cellulose, polyglycolic acid, and polyesters. © 2017 American Institute of Chemical Engineers AIChE J, 63: 1368–1383, 2017     

New techniques for the characterization of orientation in semicrystalline polymer moldings

This paper describes new techniques for evaluating orientation in polymer moldings. Injection moldings of isotactic polypropylene, a semicrystalline polymer, have been used to demonstrate the analytical procedures.     

Characterization of a glycidyl azide polymer composite propellant: Strain rate effects and relaxation response

Uniaxial tension tests were completed on a developmental GAP/PSAN solid rocket propellant at constant strain rates ranging over three decades and at five different temperatures. An analysis of the maximum stress (strength) and the strain at maximum stress showed that there is a relatively narrow range of temperatures and strain rates that give rise to strains at maximum stress that exceed 18%. The long-term equilibrium strain capability (strain endurance) appears to be between 10% and 12%. The trend of the strength and initial deformation moduli were log-linear with the reciprocal of the strain rate across three decades. However, the shifted master curves were log-curvilinear in form. The relationship between the strength and the initial modulus can be approximated by a power law. A series of stress relaxation tests was completed at a level of 4% strain and at five different temperatures. The initial portion of the shifted master relaxation curve is concave-up with correspondingly high stresses and moduli. It decays with time approaching a log-constant slope. Tensile moduli derived from constant strain rate tests were found to be consistently higher in value than the moduli as a function of time determined from relaxation tests, for an equivalent shifted time. Preliminary evidence suggests that the tensile modulus as a function of the reciprocal of shifted strain rate can be equated to the relaxation modulus as a function of shifted time through an adjustment factor. This relationship extends the relaxation modulus results back a further three and one-half decades of shifted time. © 1995 John Wiley & Sons, Inc.     

Crystalline orientation assessment in transversely isotropic semicrystalline polymer: Application to oedometric compaction of PTFE

The Hermans orientation factor is a scalar giving a simple assessment of molecular or crystal orientation in a polymer. It is usually determined from X-ray diffraction measurements. The evaluation of the Hermans orientation factor is proposed from the diffraction analysis of only a single diffracting plane. The estimation relies on (a) the assumption that the polymer crystals possess a cylindrical symmetry with respect to the chain direction and (b) that the processing conditions induce a transverse isotropy of the polymer chains. A practical consequence of the proposed analysis is that the Hermans orientation factor can be computed from a single 1D diffractogram. This enables fast evaluations since even low signal-to-noise ratio signals can be processed with optimal noise reduction. An illustration of this method for uniaxially compacted polytetrafluoroethylene (PTFE) powder is presented. The crystalline orientation is followed during in situ crystallization experiments with a fine time resolution.     

Evaluation of carbon-fiber-reinforced thermoplastic matrices in a flat braid process

An investigation was conducted to evaluate the effect of blending thermoplastic filament fibers with carbon filament fibers in varying yarn forms to study the efficiency of matrix wetting and infiltration into a laminate. Poly(etheretherketone) (PEEK) and poly(phenylene sulfide) (PPS) were studied in commingled, DREF, and powder form, as a flat triaxial braid. The as-braided and laminated specimens were both subjected to tensile testing and optical microscopy to establish the efficiency of the impregnation process. It was observed that both thermoplastic matrices commingled with carbon yarn maximized the tensile properties and produced the best quality laminate. To impart the best translational properties of the thermoplastic matrix to the carbon/thermoplastic composite, improvements are necessary in the commingling and powder infiltration processes.     

Thermal conductivity of a polymer composite

A prediction equation for thermal conductivity of polymer composites reported in our previous papers has been revised in terms of two view points: (1) estimation of thermal conductivity of a composite using an idea of reduced thermal conductivity; and (2) the effect of ease in forming conductive filler chains on thermal conductivity is related to the CVF value in electric conductivity of the composite. The new equation was confirmed to be adaptable to thermal conductivities of varieties of polymer composite systems filled with spherical or irregular fillers. The equation was also considered to explain thermal conductivity of polymer composites filled with fibers. Further, it was found that thermal conductivities of fiber composites can be estimated by introducing a factor of the CVF value or aspect ratio (L/D) into the new equation. © 1993 John Wiley & Sons, Inc.