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Method To Produce Polymer Matrix Composites

a composite material and polymer technology, applied in the field of polymer matrix composite material production, can solve the problems of significant rate-limiting steps and substantial grinding time, and achieve the effects of advancing molecular weight, eliminating rate-limiting steps, and excellent thermal stability and tribological performan

Inactive Publication Date: 2020-01-23
ATSP INNOVATIONS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The method results in ATSP composites with improved thermal stability and tribological performance, achieving densities close to theoretical values and allowing for the formation of thicker multi-material composites.

Problems solved by technology

These oligomers are typically brittle, glassy solids at room temperature which can have their particle size reduced to micron-scale powder by simple grinding with a laboratory blender.
However, substantially more grinding time was necessary due to the high mechanical properties of the ATSP resin and the reduction of the particle size becomes a significant rate-limiting step.

Method used

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  • Method To Produce Polymer Matrix Composites
  • Method To Produce Polymer Matrix Composites
  • Method To Produce Polymer Matrix Composites

Examples

Experimental program
Comparison scheme
Effect test

example 1

ped Carbon Fiber Composite

[0028]This example demonstrates the production of discontinuous ATSP composites filled with chopped carbon fiber (other chopped fibers such as glass fibers work with the same principle). First, mix the two oligomers (CB and AB) with desired weight percentage of chopped carbon fiber. Then the blended components are loaded into a mold and placed in a hot press. The hot press is ramped to 270° C. and held for one hour with no pressure applied to the mold. After one hour, the temperature is ramped to 360° C. At 360° C., the pressure is increased to 27.6 MPa (4000 psi) and the sample is held for 2 hours and then allowed to cool. An example of a fully dense discontinuous composites produced by this method (as seen in FIG. 1) is one where the filler was ¼″ chopped IM-9 carbon fiber (by Hexcel) was 28 wt. % of the composite. Initial thermal experiments on this are described below.

[0029]Thermal degradation of the composites was performed by a TGA (TA-2950) from room...

example 2

Different Fillers

[0031]As for Tribological applications, polymers in pure form as unfilled polymers may have high COF, high wear rate and poor mechanical properties, so they typically do not satisfy the tribological application needs. Thus, it is of great interest in producing composites or blended polymers by adding different fillers and reinforcements in the polymers, improving significantly their mechanical, thermal or tribological properties. In this example, we produced ATSP bearing grade composites by mixing ATSP oligomers with different fillers such as milled carbon fiber (Zoltek PX35MF0150), graphite powder, PTFE powder, carbon black, carbon nanotubes, and graphene nanoplatelets with different weight percentages. Examples of mixing ratio between ATSP and fillers that have been tried is listed in

[0032]Table 2.

TABLE 2Examples of mixing ratio between ATSP and fillersComposition of the mixtureNo.(CBAB is mixed of CB and AB oligomers with 50:50 weight ratio)1CBAB:milled carbon fi...

example 3

d—Metal Composite

[0035]Tilting pad bearings (for use in e.g. electrical submersible pumps) were fabricated using a filled composition of ATSP. A 304 stainless steel base was roughened by grit blast and subsequently cleaned via ultrasonication in isopropanol and then dried at 70° C. A mixed layer of CB and AB ground oligomeric powders (50:50 mass ratio, mesh size <90 um) were deposited via electrostatic powder deposition. The deposited coating was melted and cured via convection oven at 270° C.

[0036]The coated 304 base was inserted into a cylindrical mold as shown in FIG. 8. A blend of CB:AB oligomers (at 50:50 mass ratio) was mixed with milled carbon fiber (Zoltek PX35MF0150) and PTFE at mass proportions of 70:25:5 and thoroughly blended in a laboratory blender. Blended composition was loaded into the mold followed by the mold anvil. Loaded mold was inserted into a vacuum-enclosed hot press. A temperature cycle consisting of a 2° C. / min ramp to 270° C. followed by a 30 minute hold f...

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Abstract

This patent describes a new, simple, and low-cost method to produce aromatic thermosetting copolyester (ATSP) based polymer matrix composites. For this method, the ATSP based composites are directly produced from the blended mixtures of the ATSP oligomer powders with the composite fillers through a high temperature and high pressure curing process. In addition, the fully cured ATSP composite laminates can be bonded together to form thicker multi-material composites. The characterization showed that these ATSP based composites are fully condensed, they have excellent tribological performance (low friction and low wear rate), and they have excellent thermal stability, indicating utility in high performance bearing applications, structural materials, and as an ablative composite material.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]The present application claims priority to provisional application Ser. No. 62 / 627,337 filed Feb. 7, 2018 entitled Ablative Composites Based on Aromatic Thermosetting Copolyester, 62 / 659,844 filed Apr. 19, 2018 entitled Reversible Adhesion and Interchain Transesterification Composite Welding Mechanism, and 62 / 786,269 filed Dec. 28, 2018 entitled Adhesive and Processing Methods Utilizing Exchangeable Chemical Bonds, all of which are incorporated herein by reference in their entirety.BACKGROUND OF THE INVENTION[0002]Typically, aromatic thermosetting copolyester resins are produced by a two-part oligomerization process wherein branched aromatic crosslinkable copolyester oligomers are synthesized in a melt with average molecular weights between 1000 and 2000 g / mol with monomer feed ratios selected such that the oligomers preferentially are capped with either carboxylic acid or acetoxy functional groups. These are synthesized with an initial f...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B29C70/78B32B15/09B29C70/68B32B15/20B32B15/18
CPCB32B15/09B29C70/683B29K2309/08B29C70/78B29K2705/02B29K2105/0085B29K2067/00B29K2705/12B32B2262/106B32B15/18B29K2105/12B32B15/20B32B2262/101B29K2307/04B29B15/105B29C70/081B29C70/088B29C70/46B29C43/18B29C43/52B29C70/86B29K2105/162B29K2105/167B29K2507/04B29K2705/00B32B5/02B32B15/14B32B27/08B32B27/12B32B27/20B32B27/36B32B2255/02B32B2255/06B32B2255/26B32B2264/0257B32B2264/101B32B2264/107B32B2264/108B32B2581/00C08G63/605C08K3/04C08K3/042C08K7/06C08K2003/0806C08K2003/085C08K2201/001C09J5/06C09J11/04C09J167/00C09J2301/416C09J2301/502C09J2400/163F16B11/006B29C65/4835
Inventor LAN, PIXIANGMEYER, JACOB
Owner ATSP INNOVATIONS
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