Polymeric Composite Crystalline Phase Toughness Modulus

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Solution Overview

Problem

Existing polymeric composites face challenges in achieving a balance between low melt viscosity, high impact strength, and increased elastic modulus, as adding soft particles to improve toughness often decreases the modulus and changes process viscosity, limiting the incorporation of other reinforcements.

Innovation Solution

A polymeric composite is developed by dispersing a low molecular weight compound in the form of a crystalline phase within an organic polymer phase, where the crystalline phase is not covalently bonded and has a different molecular structure, allowing for phase separation and crystallization to enhance toughness and modulus while maintaining low melt viscosity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If soft organic polymeric particles are dispersed into the organic polymer matrix to improve impact strength and fracture toughness, then the toughness is improved, but the elastic modulus is decreased

Engineering Contradiction:

Improveimpact strengthVSAvoidelastic modulus

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The invention changes the key parameter of the dispersed phase from soft organic polymeric particles to low molecular weight compounds that form crystalline phases. This parameter change fundamentally alters the interaction mechanism: crystalline phases provide rigid reinforcement that increases elastic modulus while still enabling energy dissipation through controlled interfacial debonding and matrix yielding, thus resolving the contradiction between improving toughness and maintaining modulus

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite material system consisting of an organic polymer matrix reinforced with crystalline dispersed phases formed from low molecular weight compounds. This composite structure combines the ductility and energy absorption capability of the organic polymer matrix with the rigid reinforcement and high elastic modulus of the crystalline phases, achieving both improved toughness and maintained or enhanced modulus

Inventive Principle:

Principle #40Composite materials

2Strength

If soft particles are added to improve toughness, then the impact strength increases, but the process viscosity changes, limiting the ability to add other reinforcements

Engineering Contradiction:

Improveimpact strengthVSAvoidprocess viscosity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the physical and chemical parameters of the dispersed phase from soft polymeric particles to low molecular weight compounds that crystallize. This parameter change results in discrete, well-defined crystalline particles with controlled size and distribution, which create less drag and interference in the melt flow compared to soft particles. Consequently, the process viscosity is less affected, maintaining better processability and enabling the addition of other reinforcements

Inventive Principle:

Principle #35Parameter changes

3Strength

If soft organic polymeric particles are used to toughen the polymer, then the fracture toughness is improved, but the melt viscosity increases, reducing processability

Engineering Contradiction:

Improvefracture toughnessVSAvoidmelt viscosity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The invention creates a composite material system where low molecular weight compounds form crystalline dispersed phases within the organic polymer matrix. This composite structure provides rigid reinforcement that enhances fracture toughness through a different mechanism (controlled interfacial debonding and matrix yielding) compared to soft particles, while the crystalline nature and small size of the dispersed phase minimize interference with melt flow, thus maintaining low melt viscosity and high productivity

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite exhibits improved tensile strength, elongation at break, and impact toughness with enhanced elastic modulus, facilitating efficient melt processing and maintaining processability, while also displaying improved flame retardancy and reduced thermal expansion.

Implementation Method 1

phase separating the low molecular weight compound from the first organic polymer; wherein after the phase separation the low molecular weight compound forms a second phase

Methodology Applied

Scientific EffectPhase separation:

Implementation Method 2

crystallizing the second phase

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS8883919B2Reinforced polymetric materials, methods of manufacture thereof and articles comprising the same

Publication Date: 2014.11.11 UNIV OF MASSACHUSETTS

AI summary

Disclosed herein is a polymeric composite comprising a first organic polymer that forms a first organic polymer phase; and a low molecular weight compound that exists in the form of a second crystalline phase; wherein the second crystalline phase is dispersed within the first organic polymer phase. Disclosed herein too is a polymeric composite comprising a first organic polymer that forms a first organic polymer phase; and a second phase that comprises a crystalline organic polymer, wherein the crystalline organic polymer has a different molecular structure from the first organic polymer; wherein the second phase is not covalently bonded to the first organic polymer phase and wherein the second phase has an average particle size of about 1 to about 20 micrometers.