Table of Contents. Synthetic Polymer-Polymer Composites. Herausgegeben von Debes Bhattacharyya, Stoyko Fakirov. ISBN (Buch):

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1 Table of Contents Synthetic Polymer-Polymer Composites Herausgegeben von Debes Bhattacharyya, Stoyko Fakirov ISBN (Buch): ISBN (E-Book): For further information and order see or contact your bookseller. Carl Hanser Verlag, München

2 Contents PART I Chapter 1 INTRODUCTION Manufacturing and Processing of Polymer Composites J. Schuster, M. Duhovic, D. Bhattacharyya 1.1. Introduction Autoclave-processing Introduction Equipment Laminate assembly Process description Further developments Pultrusion Introduction Equipment Process description Filament winding and placement techniques Filament winding Tape-laying Liquid composite molding Introduction LCM processes with single sided tools Double sided tool LCM processes Thermoforming of semifinished thermoplastic composite sheets Double belt press forming Continuous compression molding Roll forming Combined forming processes Thermoforming and injection/compression molding Pultrusion/impregnation and roll forming Post processing of composites Welding of thermoplastics Conclusions and outlook...32 References:...32

3 viii Contents Chapter 2 Melting of Polymer-Polymer Composites by Particulate Heating Promoters and Electromagnetic Radiation T. Bayerl, A. Benedito Borrás, J.-I. Andrés Gallego, B. Galindo Galiana, P. Mitschang 2.1. Introduction State of the art Induction heating Microwave heating Selective melting using particulate fillers Selective melting by induction Selective melting by microwave radiation Effect of different susceptor materials Influence of dispersion quality Concepts for an industrial application Conclusions and outlook...62 Acknowledgements References...63 Further Reading Chapter 3 Inter-Particle Distance and Toughening Mechanisms in Particulate Thermosetting Composites H. S. Kim 3.1. Introduction Various conditions for fracture surface morphology Inter-particle/void distance and toughening mechanism Theoretical inter-particle distance Method for inter-particle distance measurement Statistical properties of inter-particle distance Experimental inter-void distance and toughness Toughening mechanisms in the presence of compressive stress around particles/voids Necessary conditions for cavitation Graphical understanding of compressive stress around particles Creating compressive stress around modifier particles as a toughening method... 91

4 Contents ix Production of mechanical testing specimens Mechanical properties of toughened epoxies Fracture surface morphology examination Stress intensity factor influenced by compressive residual stress Mohr circle analysis for fracture surface morphology Interaction of toughening mechanisms Conclusions References PART II Chapter 4 POLYMER-POLYMER COMPOSITES WITH PREMADE FIBROUS REINFORCEMENT Fracture Behavior of Short Carbon Fiber Reinforced Polymer Composites S. P. Bao, G. D. Liang, S. C. Tjong 4.1. Introduction Deformation of SCF-reinforced composites Carbon fiber-polymer matrix interface Fiber length Matrix microstructure Fiber orientation Fiber hybridization Fracture toughness of SCF-reinforced composites Fatigue failure Conclusions and outlook References Chapter 5 Polymer-Carbon Nanotube Composites: Melt Processing, Properties and Applications S. Pegel, T. Villmow. G. Kasaliwal, P. Pötschke 5.1. Introduction Microscopy based characterization of dispersion, distribution, and alignment of nanotubes in polymer matrices Light microscopy Transmission electron microscopy

5 x Contents 5.3. Dispersion of nanotubes by melt mixing Theoretical considerations Small-scale batch compounding Twin-screw extrusion Morphology development during shaping Compression molding Injection molding Fiber spinning Properties and applications Mechanical reinforcement Electrical conductivity Resistivity changes due to external stimuli Fire retardancy Conclusions and outlook Acknowledgments Appendix References Chapter 6 Manufacturing and Electrical Properties of Carbon Nanotube Reinforced Polymer Composites G. D. Liang, S. C. Tjong 6.1. Introduction Functionalization of carbon nanotubes Manufacturing carbon nanotube/polymer composites Solution mixing In situ polymerization Melt mixing Aligned carbon nanotube/polymer composites Electrical properties of polymer/cnt composites Percolation threshold CNT/thermoplastic nanocomposites CNT/elastomer nanocomposites Aligned CNT/polymer composites Conclusion and outlook References

6 Contents xi Chapter 7 Fabrication, Morphologies and Mechanical Properties of Carbon Nanotube Based Polymer Nanocomposites T. X. Liu, D. Chen, W. W. Tjiu 7.1. Introduction Carbon nanotubes What is carbon nanotube? Mechanical properties of carbon nanotubes Functionalization and alignment of carbon nanotubes Fabrication of polymer/carbon nanotube composites Melt compounding Solution blending In situ polymerization Other fabrication methods Mechanical properties of polymer/carbon nanotube composites Simulation results Experimental results Conclusions and outlook Acknowledgements References Chapter 8 Manufacturing and Properties of Aramid Reinforced Composites Z. Denchev, N. Dencheva 8.1. Introduction Aramid types and manufacturers Synthesis of aramids Commercial forms of aramids and their physical properties Structure and properties of p-aramid fibers Properties of p-aramid fiber reinforced polymer composites p-aramid FRPs with thermoset matrices p-aramid FRPs with thermoplastic matrices Concluding remarks Acknowledgements References

7 xii Contents Chapter 9 Molecular Liquid Crystalline Polymers Reinforced Polymer Composites: The Concept of Hairy Rods C. Fakirov 9.1. Introduction Rapid preparation technologies to exclude phase separation Advanced synthesis to obtain a homogeneous blend Homogeneous mixtures by increased enthalpy: strong dipole-dipole interaction, hydrogen bonding and ionic interactions Advanced molecular structure, consisting of rigid and flexible segments Advanced molecule structure: rigid star molecules or multipodes Molecular composites from hairy-rod molecules prepared via the Langmuir-Blodgett technique Synthesis of hairy-rod molecules Preparation of constructs of internal nanoscale architecture using the Langmuir-Blodgett technique Some properties of multilayers of hairy-rod macromolecules Construction of nanoscaled devices and functional materials Conclusions and outlook References Chapter 10 Electrospun Composite Nanofibers and Polymer Composites K. Molnár, L. M. Vas Introduction Electrospinning of nanofibers Principles of electrospinning Process optimization for gaining ultrafine nanofibers Industrialization attempts for producing electrospun materials in a high volume Modified spinnerets for higher outputs Modified collector systems for producing special electrospun structures Composite nanofibers Testing and modeling the mechanical behavior of nanofibers for composite applications Composite nanofibers incorporated with smaller nanoparticles Core-shell nanofibers prepared by coaxial electrospinning Synthetic polymer-polymer composites containing or based on electrospun nanofibers

8 Contents xiii Nanofibers as interlaminar reinforcement of composites Electrospun nanofibers and their modifications as potential reinforcement of polymer-polymer composites Conclusions and outlook Acknowledgements References PART III Chapter 11 In situ NANO- AND MICROFIBRILLAR POLYMER-POLYMER COMPOSITES The Concept of Micro- or Nanofibrils Reinforced Polymer-Polymer Composites S. Fakirov Introduction: a brief historical overview Preparation of MFC Miscibility and compatibility in polymer blends Mechanism of microfibrils formation in polymer blends and effect of the compatibilizers on this process Microfibrillar composites from blends of condensation polymers Peculiarities of MFCs prepared from blends of condensation polymers Mechanical properties of MFCs prepared from blends of condensation polymers Microfibrillar composites from blends of condensation polymers with polyolefins Nanofibrils reinforced composites from polymer blends Peculiarities of polymer nanocomposites Manufacturing of nanofibrillar polymer-polymer composites Mechanical properties of NFCs Effect of fibrils orientation on the mechanical performance of MFCs and NFCs Opportunities arising from the MFC concept Commercial potentials of the MFC concept in the automotive industry Commercial potentials of the MFC concept for commodity purposes Potential of the MFC concept for biomedical applications Conclusions and outlook Acknowledgments References

9 xiv Contents Chapter 12 Microfibril Reinforced Polymer-Polymer Composites via Hot Stretching: Preparation, Structure and Properties Y. H. Chen, G. J. Zhong, Z. M. Li Introduction Fabrication of microfibril reinforced polymer-polymer composites Rheological fundamental for deformation of dispersed phase Preparation of microfibril reinforced polymer-polymer composites Three primary factors affecting in situ fibrillation Composition Hot stretch ratio Viscosity ratio Mechanical properties of microfibril reinforced polymer-polymer composites Rheological properties of microfibril reinforced polymer-polymer composites Rheology-composition relationship of microfibril reinforced polymer-polymer composites Rheology-morphology relationship of microfibril reinforced polymer-polymer composites Crystallization property and crystal structure of microfibril reinforced polymer-polymer composites Crystallization kinetics of microfibril reinforced polymer-polymer composites Crystal structures of microfibril reinforced polymer-polymer composites Crystalline morphology and aggregates of microfibril reinforced polymer-polymer composites Application of microfibril reinforced polymer-polymer composites concept Recycling of thermoplastic blends Suppression of skin-core structure in injection molded polymer parts via in situ microfibrils Conclusions Acknowledgements References

10 Contents xv Chapter 13 Microfibril Reinforced Polymer-Polymer Composite via Hot Stretching: Electrically Conductive Functionalization Y. C. Zhang, Z. M. Li Introduction Isotropically conductive polymer composite Isotropic i-cb/pet/pe Isotropic o-cb/pet/pe Anisotropically conductive polymer composite Preparation and typical morphology The percolation behavior The resistivity-temperature behavior Conclusions Acknowledgments References Chapter 14 Preparation, Mechanical Properties and Structural Characterization of Microfibrillar Composites Based on Polyethylene/Polyamide Blends Z. Denchev, N. Dencheva Introduction Preparation and morphology of microfibrillar composites Mechanical characterization of PE/PA microfibrillar composites Tensile tests with HDPE/PA6 systems The flexural tests The impact tests A comparison between the mechanical properties of PA6 and PA12 MFCs Structure-properties relation in microfibrillar composites Microscopy studies of HDPE/PA6 and HDPE/PA12 systems Synchrotron X-ray studies of HDPE/PA6 and HDPE/PA12 MFC Conclusions and outlook Acknowledgements References

11 xvi Contents Chapter 15 Microfibrils Reinforced Composites Based on PP and PET: Effect of Draw Ratio on Morphology, Static and Dynamic Mechanical Properties, Crystallization and Rheology K. Jayanarayanan, K. Joseph, S. Thomas Introduction Experimental details: materials and procedures Sample characterization Morphology development Static mechanical properties Dynamic mechanical analysis Crystallization Dynamic rheology Conclusions and outlook References Chapter 16 Structural and Mechanical Characterization of the Reinforcement and Precursors of Micro- and Nanofibrils Reinforced Polymer-Polymer Composites N. Stribeck, D. Bhattacharyya, S. Fakirov Introduction Monitoring structure variation in polymer-polymer composites Progress in X-ray scattering Progress in methods for the analysis of scattering data Practice of experiment and data analysis WAXD fiber mapping Motivation and method design Actions required by the user Automated mapping Application X-ray scattering fiber tomography Motivation Introduction of the method Applications SAXS monitoring of mechanical tests Motivation and method development Results

12 Contents xvii Combining time resolution and spatial resolution Conclusions and outlook Acknowledgment References Chapter 17 Application Opportunities of the Microfibril Reinforced Composite Concept R. J. Shields, D. Bhattacharyya, S. Fakirov Introduction Barrier properties of polymer blends and composites Theoretical aspects of permeability How crystallinity affects permeability MFC application opportunities as packaging with improved barrier properties MFC permeation experiments Experimental setup Preliminary permeation experiments MFC permeability investigation Mechanical properties MFC permeability modeling Application opportunities in vehicle manufacturing Applications for biomedical purposes Other applications of the MFC concept Recycling of blended plastic waste streams Electroconductive materials Conclusions and outlook Acknowledgements References Chapter 18 Polylactide Based Bio-Resorbable Bone Nails: Improvements of Strength and Stiffness by Microfibrillar Reinforcement K. Friedrich, J. Hoffmann, A. A. Almajid, M. Evstatiev Introduction Materials, preparation, and characterization Materials used Specimen characterization MFC preparation

13 xviii Contents Morphology and mechanical properties Morphology of the samples Mechanical properties Conclusions Acknowledgements References PART IV Chapter 19 SINGLE POLYMER COMPOSITES Micro- and Nanofibrillar Single Polymer Composites M. Duhovic, S. Fakirov, R. Holschuh, P. Mitschang, D. Bhattacharyya Introduction Producing polymeric micro- and nanofibers Melt blowing Electrospinning Bicomponent melt spinning Mechanical properties of polymer micro- and nanofibers Characterization and modeling of the mechanical properties Manufacturing routes for micro- and nano-spc materials In situ creation of polymer micro- and nanofibrils Reactive process in situ copolymerization method Hot-compaction method Film stacking method Resin infusion method Overheating method Co-extrusion method Commercially available SPC materials Curv PURE PARA-LITE PP Armordon Kaypla Comfil SPCs and injection moldable SPC pellets (ESPRI project) Case studies SPCs by in situ creation of nanofibrils and hot compaction SPCs by melt spinning and in situ copolymerization Summary and outlook References

14 Contents xix Chapter 20 Polymorphism- and Stereoregularity-Based Single Polymer Composites J. Karger-Kocsis, S. Fakirov Introduction Definitions Preparation of single polymer composites Stereoregularity, crystallization and polymorphism in polymers Stereoregularity of macromolecules Crystallization of polymers Polymorphism in polymers Amorphous matrix with amorphous reinforcement Single polymer microcomposites Single polymer nanocomposites Amorphous matrix with semicrystalline reinforcement Single polymer microcomposites Single polymer nanocomposites Semicrystalline matrix with semicrystalline reinforcement Single polymer microcomposites Single polymer nanocomposites Applications of SPCs Outlook and future trends Acknowledgements References Chapter 21 Layered Polymer-Polymer Composite with Nanocomposite as Reinforcement W. H. Ruan, T. Czigany, T. Bárány, M. Z. Rong, M. Q. Zhang Introduction Graft polymerization onto nanoparticles Oriented PP reinforcements filled with nano-sio Manufacturing and characterization of PP homopolymer-pp copolymer composite with nanocomposite as reinforcement Conclusions Acknowledgement References

15 xx Contents Chapter 22 Manufacturing of Self-Reinforced All-PP Composites A. Bledzki, H.-P. Heim, D. Paßmann, A. Ries Introduction Self-reinforced thermoplastic fiber composite materials Manufacturing concept and composite structure Primary shaping Semifinished product manufacturing Compaction and molding Composite structure The processing technology of hot-compaction Preheating Compaction Cooling Molding strategies Thermoforming hot-compacted semifinished plate products Compression molding in combination with the hot-compaction of semifinished textile products Property spectrum of SR-PP composites Fields of application for self-reinforced organic sheets made of PP Conclusions and outlook Acknowledgement References Chapter 23 Single Polymer Composites via Shear Controlled Orientation Injection Molding (SCORIM) or Oscillating Packing Injection Molding (OPIM) Techniques J. Lei, Z.-M. Li Introduction Self-reinforced polyethylene by SCORIM techniques Self-reinforced polypropylene by SCORIM techniques Other polymer composites reinforced by SCORIM techniques Conclusions and outlook References List of Acknowledgements Author Index Subject Index