Study on the Preparation and Process Parameter-Mechanical Property Relationships of Carbon Fiber Fabric Reinforced Poly(Ether Ether Ketone) Thermoplastic Composites

Carbon fiber fabric-reinforced poly(ether ether ketone) (CFF-PEEK) composites exhibit exceptional mechanical properties, and their flexibility and conformability make them a promising alternative to traditional prepregs. However, the formation of the CFF-PEEK composite is trapped in the high viscosity of PEEK, the smooth surface, and tightly interwoven bundles of CFF. It is more difficult for the resin to flow through the fibers of complex textile structures. Here, a simple film stacking method using the hot-pressing process of plain-woven CFF-PEEK thermoplastic composites is discussed. The uniform distribution of PEEK resin between each layer of CFF reduces the flow distance during the molding process, preventing defects in the composite material effectively. Four process parameters, including molding temperature (370, 385, 400, and 415 °C), molding pressure (1, 2, 4, 8, and 10 MPa), molding time (10, 20, 30, 40, 60, and 90 min), and pre-compaction process, are considered. Interlaminar shear strength (ILSS), tensile strength, and flexural strength of CFF/PEEK composites are evaluated to optimize the process parameters. Moreover, ultrasonic scanning microscopy and scanning electron microscopy are employed to observe the formation quality and microscopic failure modes of CFF/PEEK composites, respectively. The ultimate process parameters are a molding temperature of 410 °C, molding pressure of 10 MPa, molding time of 60 min, and the need for the pre-compaction process. Under the best process parameters, the ILSS is 62.5 MPa, the flexural strength is 754.4 MPa, and the tensile strength is 796.1 MPa. This work provides valuable insight for studying the process parameters of fiber fabric-reinforced thermoplastic polymer composites and revealing their impact on mechanical properties.

Poly(ether ether ketone)s containing benzene pendant in the molecular chain: Synthesis, characterization and optical properties

A series of modified poly(ether ether ketone)s containing different content of benzene pendant group in the molecular chain have been successfully synthesized with 1,1-bis(4-hydroxyphenyl)-1-phenylethane, bisphenol A and 4,4′-difluorobenzophenone by nucleophilic substitution. The inherent viscosities of obtained polymers were in the range of 0.261–0.889 dLg−1. They were found to have high glass transition temperatures (Tg) of 150–168°C and 148–169°C (examined by DSC and DMA, respectively), good thermal stability with 5% weight-loss temperature (T5%) of 439–469°C. The tensile strengths of the obtained polymers were 67.7–86.6 MPa, and the storage modulus was over 0.9 GPa at about 140°C. The modified poly(ether ether ketone)s showed the excellent solubility property, they could be processed by solution method. Additionally, the obtained polymers had good optical transmittance (>70%) at 400 nm, suggesting that they have potential to be applied to the heat-resistant optical films.

Synthesis and characterization of poly(phthalazinone ether ketone ketone) copolymers with 4,4′-dihydroxybiphenyls

Meta-poly(phthalazinone ether ketone ketone) copolymers with 4,4′-dihydroxybiphenyls (meta-PPBEKK) was synthesized with 4,4′-dihydroxybiphenyls (BP), 1,3-bis(4-fluorobenzoyl)benzene (meta-DFKK) and 4-(4-hydroxyphenyl)-2,3-diazaphthalene-1-one (DHPZ). The copolymers are high-temperature resistant and have good solubility in many solvents. With increasing molar ratio of BP to meta-DFKK from 0 to 0.2, the addition of BP improves number-average molecular masses, intrinsic viscosity, mechanical properties and fluidity of meta-PPBEKKs. When the molar ratio of BP to meta-DFKK is 0.2, the intrinsic viscosity reaches 1.14 dL g−1, the number-average molecular mass reaches 44700 g mol−1, the maximum thermal elongation ratio reaches 14 with strength of 127.1 MPa and Young’s modulus of 2.4 GPa. With increasing molar ratio of BP to meta-DFKK from 0 to 0.2, meta-PPBEKKs have improved comprehensive properties, and make sense in many fields.

New poly(aryl ether ketone)s containing 2,6-diphenylpyridyl units and diphenylphosphinophenyl pendant groups

4-(4-Diphenylphosphino)phenyl-2,6-bis(4-hydroxyphenyl)pyridine, as a new bisphenol monomer, was prepared from 4-(diphenylphosphino)benzaldehyde and 4-hydroxyacetophenone and used in the preparation of several aromatic poly(ether ketone)s (PEKs) containing 2,6-diphenylpyridyl units and diphenylphosphinophenyl pendant groups via a nucleophilic aromatic substitution polycondensation with difluorinated aromatic ketones. The polycondensation proceeded quantitatively in tetramethylene sulfone in the presence of anhydrous potassium carbonate and afforded the polymers with high molecular weights. The resulting PEKs are amorphous and exhibit high glass transition temperatures of 209–255°C and 5% weight loss temperatures of 536–554°C with char yields of 57–62% at 800°C in nitrogen. Their high char yields and good limited oxygen index values ranging from 39 to 43 indicated these polymers exhibited good thermal stability and flame-retardant property. All new PEKs were soluble in common organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, and chloroform and could form tough, flexible, and strong films with tensile strengths of 74.6–86.8 MPa, tensile moduli of 2.9–3.6 GPa, and elongations at break of 5–9%.