High modulus high strength high flow OSU compliant polyetherimide-carbon fiber composites for metal replacement
View Patent ↗Disclosed herein are fiber reinforced thermoplastic composite with desired physical properties, such as high modulus, high stiffness and high flow while maintaining the OSU heat release compliancy.
1. A fiber reinforced thermoplastic composite, comprising a continuous thermoplastic polymer phase comprising:
a) a polyetherimide having a molecular weight of at least 40,000 Daltons; and a polyetheretherketone having a melt viscosity less than 150 Pascal-seconds (Pa-s) when determined under the conditions of 400° C. and a shear rate of 1000/s; and
b) a dispersed phase comprising a plurality of polyacrylonitrile-based carbon fibers having a tensile modulus in the range of from 38 to 48 MSI dispersed within the continuous thermoplastic polymer phase; and
wherein the composite exhibits a specific modulus of at least about 25; wherein the composite exhibits a tensile strength of at least about 226 MPa; wherein the composite exhibits a melt mass-flow rate (“MFR”) of at least 10 g/min when determined under the conditions of 380° C. and 6.6 kg mass; and wherein the composite exhibits a heat release profile characterized by a 2 minute total heat release less than about 65 kW min/m 2 and a peak heat release rate less than about 65 kW/m 2 when measured according to the Ohio State University (“OSU”) Heat Release test.
2. The composite of claim 1 , wherein the polyetherimide has a molecular weight of at least about 50,000 Daltons.
3. The composite of claim 1 , wherein the polyetherimide is present in an amount that does not exceed about 60 wt % of the composite.
4. The composite of claim 1 , wherein the polyetherimide is present in an amount in the range of from about 40 wt % to about 60 wt % of the composite.
5. The composite of claim 1 , wherein the polyetheretherketone is present in an amount in the range of from about 10 wt % to 60 wt % of the continuous thermoplastic polymer phase.
6. The composite of claim 1 , wherein the polytheretherketone has a melt viscosity less than about 100 Pascal-seconds (Pa-s) when determined under the conditions of 400° C. and a shear rate of 1000/s.
7. The composite of claim 1 , wherein the plurality of carbon fibers are present in an amount that is at least about 35 wt % of the total weight of the composite.
8. A fiber reinforced thermoplastic composite, comprising:
a) a continuous thermoplastic polymer phase comprising:
i. a polyetherimide having a molecular weight of at least about 40,000 Daltons, wherein the polyetherimide resin is present in the composite in an amount that does not exceed about 60 wt % of the composite;
ii. a polyetheretherketone having a melt viscosity less than 150 Pascal-seconds (Pa-s) when determined under the conditions of 400° C. and a shear rate of 1000/s, wherein the polyetheretherketone is present in the composite in an amount in the range of from about 10 wt % to about 60 wt % of the continuous thermoplastic polymer phase; and
b) a dispersed phase comprising a plurality of polyacrylonitrile-based carbon fibers having a tensile modulus in the range of from 38 to 48 MSI dispersed within the continuous thermoplastic polymer phase, wherein the plurality of polyacrylonitrile-based carbon fibers are present in an amount that is at least about 35 wt % of the total weight of the composite.
9. The composite of claim 8 , wherein the composite exhibits a specific modulus of at least about 25; wherein the composite exhibits a tensile strength of at least about 226 MPa; wherein the composite exhibits a melt mass-flow rate (“MFR”) of at least 10 g/min when determined under the conditions of 380° C. and 6.6 kg mass; and wherein the composite exhibits a heat release profile, as measured according to the Ohio State University (“OSU”) Heat Release test, characterized by a 2 minute total heat release rate less than 65 kW min/m 2 and a peak heat release less than 65 kW/m 2 .