Impact Modified Composite Composition
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Solution Overview
Problem
Current composite materials used in mechanical parts face limitations in impact strength due to the fragility of thermoplastic polymers, which hinder the effective dispersion of multistage polymer particles, leading to inadequate mechanical properties and high viscosity issues during impregnation of fibrous substrates.
Innovation Solution
A composition comprising a fibrous material, a multistage polymer, and a (meth)acrylic polymer is developed, allowing for stable and homogeneous distribution of the multistage polymer particles within the matrix, enhancing impact strength and processing efficiency by controlling viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermoplastic polymers are used as matrix material, then the composite material can be reformed and reprocessed, but the matrix remains fragile and does not have good mechanical properties such as impact strength
Solution Approach 1:
The patent uses a composite matrix system combining thermoplastic polymer with elastomeric phase (rubber particles) to achieve both reprocessability and improved impact strength. The thermoplastic matrix provides reprocessability while the dispersed elastomeric particles enhance toughness and impact resistance, creating a composite material that overcomes the fragility of pure thermoplastic polymers.
2Strength
If multistage polymer particles are added to improve impact strength, then the composite material gains toughness, but the particles are difficult to disperse homogeneously in the matrix
Solution Approach 1:
The patent modifies the surface characteristics and size parameters of multistage polymer particles to improve their dispersibility in the thermoplastic matrix. By controlling particle size, surface treatment, and composition parameters, the patent achieves homogeneous distribution of impact modifiers throughout the matrix, resolving the dispersion difficulty while maintaining impact strength enhancement.
3Ease of operation
If thermoplastic polymer is heated to reduce viscosity for impregnation, then the fluidity improves, but the high viscosity in molten state still hinders homogeneous impregnation of fibrous substrate
Solution Approach 1:
The patent modifies the thermoplastic polymer's molecular weight, composition, and thermal parameters to reduce melt viscosity while maintaining mechanical properties. By adjusting these parameters, the patent achieves sufficient fluidity for easy impregnation of fibrous substrates while ensuring homogeneous distribution and complete wetting during the molding process.
4Strength
If impact additive comprising elastomeric phase is added to improve impact strength, then the toughness increases, but the particle size must be less than 1 μm which complicates the formulation
Solution Approach 1:
The patent optimizes the elastomeric particle size parameter to be less than 1 μm (specifically 0.1-0.5 μm) and controls the concentration and composition parameters to achieve effective impact modification without excessive formulation complexity. This parameter optimization ensures proper dispersion and effectiveness while maintaining practical manufacturability.
Data Source
AI summary
The present invention relates to a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer. The composition can be in form of a prepreg, a preform or a laminate. In particular the present invention it relates to a method for making a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer and its use in making composite articles. More particularly the present invention relates to a process for preparing a composition comprising a fibrous material, a multistage polymer and a (meth)acrylic polymer and its use for producing fibre reinforced impact modified composites.