Fibers sized with polyetherketoneketones
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Solution Overview
Problem
Many polymeric resins, especially highly crystalline engineering thermoplastics, exhibit poor adhesion to fiber surfaces, limiting the potential properties of fiber-reinforced composites, and existing sizing compositions have unsatisfactory stability at high processing temperatures.
Innovation Solution
Applying a coating of amorphous polyetherketoneketone to fibers to enhance compatibility and adhesion with polymeric matrices, particularly crystalline thermoplastics, by adjusting the Formula I:Formula II ratio to create a non-crystalline polymer that forms a thin, stable coating on the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If highly crystalline engineering thermoplastics are used as polymeric resins, then mechanical strength and thermal stability are improved, but adhesion to fiber surfaces deteriorates
Solution Approach 1:
The patent applies an amorphous polyetherketoneketone sizing composition as an intermediary layer between the fiber surface and the highly crystalline engineering thermoplastic matrix. This sizing layer acts as a mediator that provides good adhesion to both the fiber and the crystalline polymer, resolving the adhesion problem while maintaining the mechanical strength benefits of the crystalline resin.
Solution Approach 2:
The patent changes the crystallinity parameter of the polyetherketoneketone from crystalline to amorphous form for the sizing composition. This parameter change allows the sizing to provide better adhesion and stability at high processing temperatures while the final composite still utilizes highly crystalline engineering thermoplastics for mechanical strength.
2Ease of manufacture
If conventional sizing compositions are used, then ease of processing is improved, but stability at high processing temperatures deteriorates
Solution Approach 1:
The patent changes the thermal stability parameter of the sizing composition by using amorphous polyetherketoneketone with a glass transition temperature above the processing temperature of the crystalline polymer. This parameter change ensures the sizing remains stable and does not degrade or migrate during high-temperature processing, while still providing ease of application and processing.
3Reliability
If amorphous polyetherketoneketone sizing is applied to fibers, then adhesion and stability are improved, but manufacturing complexity increases
Solution Approach 1:
The amorphous polyetherketoneketone sizing composition serves multiple functions simultaneously: it provides adhesion between fiber and matrix, acts as a thermal stabilizer during high-temperature processing, and maintains processability. This multi-functionality reduces the need for additional specialized treatments or materials, thereby limiting the increase in manufacturing complexity.
Data Source
AI summary
Fibers sized with a coating of amorphous polyetherketoneketone are useful in the preparation of reinforced polymers having improved properties, wherein the amorphous polyetherketoneketone can improve the compatibility of the fibers with the polymeric matrix.