End‐functionalized thermoplastic‐toughened phthalonitrile composites: influence on cure reaction and mechanical and thermal properties

Phthalonitrile polymers are known for their high thermal stability and good mechanical properties. However, their brittle nature limits their application as structural composites in many critical areas. The present study investigates the feasibility of toughening novolac–phthalonitrile (NPN) resin using chemically modified poly(ether ether ketone) (PEEK). A telechelic PEEK bearing a phthalonitrile end group (PEEKPN) was synthesized via nucleophilic substitution of nitrophthalonitrile with the corresponding phenol–telechelic poly(ether ether ketone) (PEEKOH). Different compositions of NPN and PEEKOH–PEEKPN blends with curing agent, i.e. diaminodiphenylsulfone, were investigated for their cure behaviour and mechanical properties of their carbon fabric composites. In NPN–PEEKOH blends, crosslinking of the phthalonitrile groups was facilitated by phenol‐mediated reactions resulting in the reduction of cure temperatures by around 130 °C with substantial improvement in thermal stability. Blending the resin with the thermoplastic enhanced the mechanical properties of the composites. The apparent flexural strength and impact strength of carbon fabric‐reinforced composites were improved by more than 200 and 150%, respectively, on incorporation of 20 wt% PEEKOH in the NPN matrix. However, higher concentration of PEEKOH had a detrimental effect on the properties. Substitution of phenol end groups by phthalonitrile moieties led to integration of the PEEK moieties with the NPN matrix. However, it was not as conducive as PEEKOH for improving the matrix properties. The better performance of PEEKOH is attributed to the formation of polar heterocyclic groups like isoindoline by way of the phenol–nitrile reaction. © 2014 Society of Chemical Industry