High strength high impact high flow OSU compliant polyetherimide-carbon fiber composites
View Patent ↗Disclosed herein are fiber reinforced thermoplastic composite with desired physical properties, such as high strength, high impact 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 less than or equal to about 40,000 Daltons; a polyetheretherketone having a melt viscosity less than about 150 Pascal-seconds (Pa-s) when determined under the conditions of 400° C. and a shear rate of 1000/s; and a polyetherimide-siloxane copolymer; and
b) a dispersed phase comprising a plurality of polyacrylonitrile based carbon fibers having a tensile strength in the range of from about 500 to about 1,200 kilo-pounds per square inch (“KSI”) dispersed within the continuous thermoplastic polymer phase; and
wherein the composite exhibits a notched Izod impact strength of at least about 75 J/m; wherein the composite exhibits an unnotched Izod impact strength of at least about 500 J/m; wherein the composite exhibits a melt mass-flow rate (“MFR”) of at least about 40 g/10 min when determined under the conditions of 380° C. and 6.6 kg mass in accordance with ASTM D1238; wherein the composite exhibits a heat release profile characterized by a 2 minute total heat release less than about 65 kW/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 less than or equal to about 40,000 Daltons.
3. The composite of claim 1 , wherein the polyetherimide is present in an amount that does not exceed about 70 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 40 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 20 wt % of the total weight of the composite.
8. The composite of claim 1 , wherein the polyetherimide-siloxane copolymer is present in an amount from about 2 wt % to about 8 wt %.
9. A fiber reinforced thermoplastic composite, comprising:
a) a continuous thermoplastic polymer phase comprising:
i. a polyetherimide having a molecular weight of less than or equal to about 40,000 Daltons, wherein the polyetherimide resin is present in the composite in an amount that does not exceed about 70 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 40 wt % of the continuous thermoplastic polymer phase; and
iii. a polyetherimide-siloxane copolymer, wherein the polyetherimide-siloxane copolymer is present in an amount of at least about 1 wt % of the composite; and
b) a dispersed phase comprising a plurality of carbon fibers having a tensile strength in the range of from about 500 to about 1,200 kilo-pounds per square inch (“KSI”) dispersed within the continuous thermoplastic polymer phase, wherein the plurality of carbon fibers are present in an amount that is at least about 20 wt % of the total weight of the composite.
10. The composite of claim 9 , wherein the composite exhibits a notched Izod impact strength of at least about 75 J/m; wherein the composite exhibits an unnotched Izod impact strength of at least about 500 J/m; wherein the composite exhibits a melt mass-flow rate (“MFR”) of at least about 40 g/10 min when determined under the conditions of 380° C. and 6.6 kg mass in accordance with ASTM D1238; wherein the composite exhibits a heat release profile characterized by a 2 minute total heat release less than about 65 kW/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.
11. The composite of claim 1 , wherein the polyetheretherketone is not a polyphenylsulfone polymer.