Synthetic Polymer-Polymer Composites

Preface

Contents

Contributors

PART I – INTRODUCTION

Chapter 1 – Manufacturing and Processing of Polymer Composites

1.1. Introduction

1.2. Autoclave-processing

1.2.1. Introduction

1.2.2. Equipment

1.2.3. Laminate assembly

1.2.4. Process description

1.2.5. Further developments

1.3. Pultrusion

1.3.1. Introduction

1.3.2. Equipment

1.3.3. Process description

1.4. Filament winding and placement techniques

1.4.1. Filament winding

1.4.2. Tape-laying

1.5. Liquid composite molding

1.5.1. Introduction

1.5.2. LCM processes with single sided tools

1.5.3. Double sided tool LCM processes

1.6. Thermoforming of semifinished thermoplastic composite sheets

1.6.1. Double belt press forming

1.6.2. Continuous compression molding

1.6.3. Roll forming

1.7. Combined forming processes

1.7.1. Thermoforming and injection/compression moldi

1.7.2. Pultrusion/impregnation and roll formin

1.8. Post processing of composites

1.8.1. Welding of thermoplastics

1.9. Conclusions and outlook

References

Chapter 2 – Melting of Polymer-Polymer Compositesby Particulate Heating Promotersand Electromagnetic Radiation

2.1. Introduction

2.2. State of the art

2.2.1. Induction heating

2.2.2. Microwave heating

2.3. Selective melting using particulate fillers

2.3.1. Selective melting by induction

2.3.1.1. Effect of different susceptor materials

2.3.1.2. Effect of frequency variation

2.3.1.3. Effect of susceptor size

2.3.1.4. Application of induction heating for polymer-polymer materials

2.3.1.5. Simulation of particulate inductive heating

2.4. Selective melting by microwave radiation

2.4.1. Effect of different susceptor materials

2.4.2. Influence of dispersion quality

2.5. Concepts for an industrial application

2.6. Conclusions and outlook

Acknowledgements

References

Further Reading

Chapter 3 – Inter-Particle Distance and TougheningMechanisms in Particulate ThermosettingComposites

3.1. Introduction

3.2. Various conditions for fracture surface morphology

3.3. Inter-particle/void distance and toughening mecha

3.3.1. Theoretical inter-particle distance

3.3.2. Method for inter-particle distance measurement

3.3.3. Statistical properties of inter-particle distance

3.3.3.1. 3D particle generation

3.3.3.2. Results and discussion

3.3.4. Experimental inter-void distance and toughness

3.3.4.1. Method for void generation in matrix

3.3.4.2. Mechanical testing

3.3.4.3. Microscopy

3.3.4.4. Experimental results and discussion

3.4. Toughening mechanisms in the presence of compressive stress around particles/voids

3.4.1. Necessary conditions for cavitation

3.4.2. Graphical understanding of compressive stress around particles

3.4.3. Creating compressive stress around modifier particles as a toughening method

3.4.4. Production of mechanical testing specimens

3.4.5. Mechanical properties of toughened epoxies

3.4.6. Fracture surface morphology examination

3.4.7. Stress intensity factor influenced by compressive residual stress

3.4.8. Mohr circle analysis for fracture surface morphology

3.4.9. Interaction of toughening mechanisms

3.5. Conclusions

References

PART II – POLYMER-POLYMER COMPOSITES WITH PREMADE FIBROUS REINFORCEMENT

Chapter 4 – Fracture Behavior of Short Carbon Fiber Reinforced Polymer Composites

4.1. Introduction

4.2. Deformation of SCF-reinforced composites

4.2.1. Carbon fiber-polymer matrix interface

4.2.2. Fiber length

4.2.3. Matrix microstructure

4.2.4. Fiber orientation

4.3. Fiber hybridization

4.4. Fracture toughness of SCF-reinforced composites

4.5. Fatigue failure

4.6. Conclusions and outlook

References

Chapter 5 – Polymer-Carbon Nanotube Composites: Melt Processing, Properties and Applications

5.1. Introduction

5.2. Microscopy based characterization of dispersion, distribution, and alignment of nanotubes in polymer matrices

5.2.1. Light microscopy

5.2.2. Transmission electron microscopy

5.3. Dispersion of nanotubes by melt mixing

5.3.1. Theoretical considerations

5.3.2. Small-scale batch compounding

5.3.3. Twin-screw extrusion

5.4. Morphology development during shaping

5.4.1. Compression molding

5.4.2. Injection molding

5.4.3. Fiber spinning

5.5. Properties and applications

5.5.1. Mechanical reinforcement

5.5.2. Electrical conductivity

5.5.3. Resistivity changes due to external stimuli

5.5.4. Fire retardancy

5.6. Conclusions and outlook

Acknowledgments

Appendix

References

Chapter 6 – Manufacturing and Electrical Properties of Carbon Nanotube Reinforced Polymer Composites

6.1. Introduction

6.2. Functionalization of carbon nanotubes

6.3. Manufacturing carbon nanotube/polymer composites

6.3.1. Solution mixing

6.3.2. In situ polymerization

6.3.3. Melt mixing

6.3.5. Aligned carbon nanotube/polymer composites

6.4. Electrical properties of polymer/CNT composites

6.4.1. Percolation threshold

6.4.2. CNT/thermoplastic nanocomposites

6.4.2.1. Glassy thermoplastics

6.4.2.2. Semicrystalline thermoplastics

6.4.3. CNT/elastomer nanocomposites

6.4.4. Aligned CNT/polymer composites

6.5. Conclusion and outlook

References

Chapter 7 – Fabrication, Morphologies and Mechanical Properties of Carbon Nanotube Based Polymer Nanocomposites

7.1. Introduction

7.2. Carbon nanotubes

7.2.1. What is carbon nanotube?

7.2.2. Mechanical properties of carbon nanotubes

7.2.3. Functionalization and alignment of carbon nanotubes

7.3. Fabrication of polymer/carbon nanotube composites

7.3.1. Melt compounding

7.3.2. Solution blending

7.3.3. In situ polymerization

7.3.4. Other fabrication methods

7.4. Mechanical properties of polymer/carbon nanotube composites

7.4.1. Simulation results

7.4.2. Experimental results

7.5. Conclusions and outlook

Acknowledgements

References

Chapter 8 – Manufacturing and Properties of Aramid Reinforced Composites

8.1. Introduction

8.2. Aramid types and manufacturers

8.3. Synthesis of aramids

8.4. Commercial forms of aramids and their physical properties

8.5. Structure and properties of p-aramid fibers

8.6. Properties of p-aramid fiber reinforced polymer composites

8.6.1. p-Aramid FRPs with thermoset matrices

8.6.1.1. Unsaturated polyester and vinyl ester matrices

8.6.1.2. Epoxy resin matrices

8.6.1.3. Other thermoset matrices for p-aramid composites

8.6.1.4. Manufacturing of p-aramid composites with thermoset matrices

8.6.2. p-Aramid FRPs with thermoplastic matrices

8.7. Concluding remarks

Acknowledgements

References

Chapter 9 – Molecular Liquid Crystalline Polymers Reinforced Polymer Composites: The Concept of “Hairy Rods”

9.1. Introduction

9.1.1. Rapid preparation technologies to exclude phase separation

9.1.2. Advanced synthesis to obtain a homogeneous blend

9.1.3. Homogeneous mixtures by increased enthalpy: strong dipole-dipole interaction, hydrogen bonding and ionic interactions

9.1.4. Advanced molecular structure, consisting of rigid and flexible segments

9.1.5. Advanced molecule structure: rigid star molecules or multipodes

9.2. Molecular composites from “hairy-rod” molecules prepared via the Langmuir-Blodgett technique

9.2.1. Synthesis of “hairy-rod” molecules

9.2.2. Preparation of constructs of internal nanoscale architecture using the Langmuir-Blodgett technique

9.2.3. Some properties of multilayers of hairy-rod macromolecules

9.2.4. Construction of nanoscaled devices and functional materials

9.3. Conclusions and outlook

References

Chapter 10 – Electrospun Composite Nanofibers and Polymer Composites

10.1. Introduction

10.2. Electrospinning of nanofibers

10.2.1. Principles of electrospinning

10.2.2. Process optimization for gaining ultrafine nanofibers

10.3. Industrialization attempts for producing electrospun materials in a high volume

10.3.1. Modified spinnerets for higher outputs

10.3.2. Modified collector systems for producing special electrospun structures

10.4. Composite nanofibers

10.4.1. Testing and modeling the mechanical behavior of nanofibers for composite applications

10.4.2. Composite nanofibers incorporated with smaller nanoparticles

10.4.3. Core-shell nanofibers prepared by coaxial electrospinning

10.5. Synthetic polymer-polymer composites containing or based on electrospun nanofibers

10.5.1. Nanofibers as interlaminar reinforcement of composites

10.5.2. Electrospun nanofibers and their modifications as potential reinforcement of polymer-polymer composites

10.6. Conclusions and outlook

Acknowledgements

References

PART III – In situ NANO- AND MICROFIBRILLARPOLYMER-POLYMER COMPOSITES

Chapter 11 – The Concept of Micro- or NanofibrilsReinforced Polymer-Polymer Composites

11.1. Introduction: a brief historical overview

11.2. Preparation of MFC

11.2.1. Miscibility and compatibility in polymer blends

11.3. Mechanism of microfibril formation in polymer blends and effect of the compatibilizers on this process

11.4. Microfibrillar composites from blends of condensation polymers

11.4.1. Peculiarities of MFCs prepared from blends of condensation polymers

11.4.2. Mechanical properties of MFCs prepared from blends of condensation polymers

11.5. Microfibrillar composites from blends of condensation polymers with polyolefins

11.6. Nanofibril reinforced composites from polymer blends

11.6.1. Peculiarities of polymer nanocomposites

11.6.2. Manufacturing of nanofibrillar polymer-polymer composites

11.6.4. Mechanical properties of NFCs

11.7. Effect of fibril orientation on the mechanical performance of MFCs and NFCs

11.8. Opportunities arising from the MFC concept

11.8.1. Commercial potential of the MFC concept in the automotive industry

11.8.2. Commercial potential of the MFC concept for commodity purposes

11.8.3. Potential of the MFC concept for biomedical applications

11.9. Conclusions and outlook

Acknowledgments

References

Chapter 12 – Microfibril Reinforced Polymer-Polymer Composites via Hot Stretching: Preparation, Structure and Properties

12.1. Introduction

12.2. Fabrication of microfibril reinforced polymer-polymer composites

12.2.1. Rheological fundamental for deformation of dispersed phase

12.2.2. Preparation of microfibril reinforced polymer-polymer composites

12.3. Three primary factors affecting in situ fibrillation

12.3.1. Composition

12.3.2. Hot stretch ratio

12.3.3. Viscosity ratio

12.4. Mechanical properties of microfibril reinforced polymer-polymer composites

12.5. Rheological properties of microfibril reinforced polymer-polymer composites

12.5.1. Rheology-composition relationship of microfibril reinforced polymer-polymer composites

12.5.2. Rheology-morphology relationship of microfibril reinforced polymer-polymer composites

12.6. Crystallization property and crystal structure of microfibril reinforced polymer-polymer composites

12.6.1. Crystallization kinetics of microfibril reinforced polymer-polymer composites

12.6.2. Crystal structures of microfibril reinforced polymer-polymer composites

12.6.3. Crystalline morphology and aggregates of microfibril reinforced polymer-polymer composites

12.7. Application of microfibril reinforced polymer-polymer composites concept

12.7.1. Recycling of thermoplastic blends

12.7.2. Suppression of skin-core structure in injection molded polymer parts via in situ microfibrils

12.8. Conclusions

Acknowledgements

References

Chapter 13 – Microfibril Reinforced Polymer-Polymer Composite via Hot Stretching: Electrically Conductive Functionalization

13.1. Introduction

13.2. Isotropically conductive polymer composite

13.2.1. Isotropic i-CB/PET/PE

13.2.1.1. Preparation and typical morphology

13.2.1.2. The percolation behavior

13.2.1.3. The resistivity-temperature behavior

13.2.2. Isotropic o-CB/PET/PE

13.2.2.1. Preparation and typical morphology

13.2.2.2. The percolation behavior

13.2.2.3. The resistivity-temperature behavior during cooling

13.3. Anisotropically conductive polymer composite

13.3.1. Preparation and typical morphology

13.3.2. The percolation behavior

13.3.3. The resistivity-temperature behavior

13.4. Conclusions

Acknowledgments

References

Chapter 14 – Preparation, Mechanical Properties and Structural Characterization of Microfibrillar Composites Based on Polyethylene/Polyamide Blends

14.1. Introduction

14.2. Preparation and morphology of microfibrillar composites

14.3. Mechanical characterization of PE/PA microfibrillar composites

14.3.1. Tensile tests with HDPE/PA6 systems

14.3.2. The flexural tests

14.3.3. The impact tests

14.3.4. A comparison between the mechanical properties of PA6 and PA12 MFCs

14.4. Structure-properties relation in microfibrillar composites

14.4.1. Microscopy studies of HDPE/PA6 and HDPE/PA12 systems

14.4.2. Synchrotron X-ray studies of HDPE/PA6 and HDPE/PA12 MFC

14.4.2.1. Small-angle X-ray scattering

14.4.2.2. Wide-angle X-ray scattering

14.4.2.3. Evaluation of the TCL thickness

14.5. Conclusions and outlook

Acknowledgements

References

Chapter 15 – Microfibrils Reinforced Composites Based on PP and PET: Effect of Draw Ratioon Morphology, Static and Dynamic Mechanical Properties, Crystallization and Rheology

15.1. Introduction

15.2. Experimental details: materials and procedures

15.3. Sample characterization

15.3.1. Morphology development

15.3.2. Static mechanical properties

15.3.2.1. Tensile properties

15.3.2.2. Flexural and impact properties

15.3.3. Dynamic mechanical analysis

15.3.3.1. Storage modulus

15.3.3.2. Loss modulus

15.3.3.3. Mechanical loss factor (tan d)

15.3.4. Crystallization

15.3.4.1. Non-isothermal crystallization behavior of MFBs and MFCs

15.3.4.2. Crystallization time

15.3.4.3. X-ray diffraction

15.3.5. Dynamic rheology

15.3.5.1. Storage and loss shear modulus

15.3.5.2. Complex viscosity and tan d

15.4. Conclusions and outlook

References

Chapter 16 – Structural and Mechanical Characterization of the Reinforcement and Precursors of Micro- and Nanofibrils Reinforced Polymer-Polymer Composites

16.1. Introduction

16.1.1. Monitoring structure variation in polymer-polymer composites

16.1.2. Progress in X-ray scattering

16.1.3. Progress in methods for the analysis of scattering data

16.2. Practice of experiment and data analysis

16.3. WAXD fiber mapping

16.3.1. Motivation and method design

16.3.2. Actions required by the user

16.3.3. Automated mapping

16.3.4. Application

16.4. X-Ray scattering fiber tomography

16.4.1. Motivation

16.4.2. Introduction of the method

16.4.3. Applications

16.5. SAXS monitoring of mechanical tests

16.5.1. Motivation and method development

16.6. Combining time resolution and spatial resolution

16.7. Conclusions and outlook

Acknowledgment

References

Chapter 17 – Application Opportunities of the Microfibril Reinforced Composite Concept

17.1. Introduction

17.2. Barrier properties of polymer blends and composites

17.2.1. Theoretical aspects of permeability

17.2.2. How crystallinity affects permeability

17.3. MFC application opportunities as packaging with improved barrier properties

17.4. MFC permeation experiments

17.4.1. Experimental setup

17.4.2. Preliminary permeation experiments

17.4.2.1. Effect of PET content

17.4.2.2. Effect of draw ratio

17.4.3. MFC permeability investigation

17.4.3.1. Manufacturing parameters

17.4.3.2. Film morphology

17.4.3.3. Permeability Test Results

17.4.3.4. Analysis using the Taguchi method

17.4.3.5. Sample crystallinity

17.4.3.6. The role of aging

17.4.4. Mechanical properties

17.5. MFC permeability modeling

17.6. Application opportunities in vehicle manufacturing

17.7. Applications for biomedical purposes

17.8. Other applications of the MFC concept

17.8.1. Recycling of blended plastic waste streams

17.8.2. Electroconductive materials

17.9. Conclusions and outlook

Acknowledgements

References

Chapter 18 – Polylactide Based Bio-Resorbable Bone Nails: Improvements of Strength and Stiffness by Microfibrillar Reinforcement

18.1. Introduction

18.2. Materials, preparation, characterization

18.2.1. Materials used

18.2.2. Specimen characterization

18.2.3. MFC preparation

18.3. Morphology and mechanical properties

18.3.1. Morphology of the samples

18.3.2. Mechanical properties

18.4. Conclusions

Acknowledgements

References

PART IV – SINGLE POLYMER COMPOSITES

Chapter 19 – Micro- and Nanofibrillar Single Polymer Composites

19.1. Introduction

19.2. Producing polymeric micro- and nanofibers

19.2.1. Melt blowing

19.2.2. Electrospinning

19.2.3. Bicomponent melt spinning

19.3. Mechanical properties of polymer micro- and nanofibers

19.3.1. Characterization and modeling of the mechanical properties

19.4. Manufacturing routes for micro- and nano-SPC materials

19.4.1. In situ creation of polymer micro- and nanofibrils

19.4.2. Reactive process in situ copolymerization method

19.4.3. Hot-compaction method

19.4.4. Film stacking method

19.4.5. Resin infusion method

19.4.6. Overheating method

19.4.7. Co-extrusion method

19.5. Commercially available SPC materials

19.5.1. Curv

19.5.2. PURE

19.5.3. PARA-LITE PP

19.5.4. Armordon

19.5.5. Kaypla

19.5.6. Comfil SPCs and injection moldable SPC pellets (ESPRI project)

19.6. Case studies

19.6.1. SPCs by in situ creation of nanofibrils and hot compaction

19.6.2. SPCs by melt spinning and in situ copolymerization

19.7. Summary and outlook

References

Chapter 20 – Polymorphism- and Stereoregularity-Based Single Polymer Composites

20.1. Introduction

20.1.1. Definitions

20.1.2. Preparation of single polymer composites

20.2. Stereoregularity, crystallization and polymorphism in polymers

20.2.1. Stereoregularity of macromolecules

20.2.2. Crystallization of polymers

20.2.3. Polymorphism in polymers

20.3. Amorphous matrix with amorphous reinforcement

20.3.1. Single polymer microcomposites

20.3.2. Single polymer nanocomposites

20.4. Amorphous matrix with semicrystalline reinforcement

20.4.1. Single polymer microcomposites

20.4.2. Single polymer nanocomposites

20.5. Semicrystalline matrix with semicrystalline reinforcement

20.5.1. Single polymer microcomposites

20.5.2. Single polymer nanocomposites

20.6. Applications of SPCs

20.7. Outlook and future trends

Acknowledgements

References

Chapter 21 – Layered Polymer-Polymer Composite with Nanocomposite as Reinforcement

21.1. Introduction

21.2. Graft polymerization onto nanoparticles

21.3. Oriented PP reinforcements filled with nano-SiO2

21.4. Manufacturing and characterization of PP homopolymer-PP copolymer composite with nanocomposite as reinforcement

21.5. Conclusions

Acknowledgement

References

Chapter 22 – Manufacturing of Self-Reinforced All-PPComposites

22.1. Introduction

22.2. Self-reinforced thermoplastic fiber composite materials

22.3. Manufacturing concept and composite structure

22.3.1. Primary shaping

22.3.2. Semifinished product manufacturing

22.3.3. Compaction and molding

22.3.4. Composite structure

22.4. The processing technology of hot-compaction

22.5. Molding strategies

22.4.1. Preheating

22.4.2. Compaction

22.4.3. Cooling

22.5. Molding strategies

22.5.1. Thermoforming hot-compacted semifinished plate products

22.5.2. Compression molding in combination with the hot-compaction of semifinished textile products

22.6. Property spectrum of SR-PP composites

22.7. Fields of application for self-reinforced organic sheets made of PP

22.8. Conclusions and outlook

Acknowledgement

References

Chapter 23 – Single Polymer Composites via Shear Controlled Orientation Injection Molding (SCORIM) or Oscillating Packing Injection Molding (OPIM) Techniques

23.1. Introduction

23.2. Self-reinforced polyethylene by SCORIM techniques

23.3. Self-reinforced polypropylene by SCORIM techniques

23.4. Other polymer composites reinforced by SCORIM techniques

23.5. Conclusions and outlook

References

List of Acknowledgements

Author Index

Subject Index