Method To Produce Polymer Matrix Composites

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.

1 . A method of producing aromatic thermosetting copolyester (ATSP) based composites, comprising:
 preparing mixtures of ATSP oligomer powders and fillers;   curing the mixture of ATSP oligomer powders and fillers at an elevated temperature, ranged between 270° C. and 400° C. to create a cured mixture;   consolidating the cured mixture in a high pressure, ranged between 0.1 MPa and 20 MPa; and   wherein the ATSP oligomer powders consist of pairs of carboxylic acid-capped and acetoxy-capped oligomers, and wherein the fillers consist of discontinuous fillers and continuous fillers; and wherein the discontinuous fillers consist of milled carbon fiber, chopped carbon fiber, chopped glass fiber, milled glass fiber, ceramic powder, graphite, carbon nano tubes, graphene, and polytetrafluorethylene (PTFE) powder; and wherein the continuous fillers consist of continuous carbon fiber and continuous glass fiber, in the formats of weave sheet, unidirectional fabric sheet, unidirectional tow.   
     
     
         2 . The method of  claim 1 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by adding of ATSP oligomer powders and discontinuous fillers in a predetermined weight ratios and then blending together in a blender. 
     
     
         3 . The method of  claim 1 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by depositing of ATSP oligomer powders on continuous fillers with a solvent free method, and wherein the solvent free method consists of one of the following: dry powder bath, dry powder spray, and wet slurry. 
     
     
         4 . The method of  claim 1 , wherein the step of curing the mixture of ATSP oligomer powders includes a temperature between 270° C. and 400° C., and wherein the ATSP oligomer powders are formed by crosslinking the carboxylic acid-capped oligomer and the acetoxy-capped oligomer. 
     
     
         5 . The method of  claim 1 , wherein the consolidation of cured mixture is achieved by setting a pressure 0.1 MPa and 20 MPa during a temperature range of 270° C. and 400° C. 
     
     
         6 . A method of producing aromatic thermosetting copolyester (ATSP) based composites attached on metal substrate, comprising:
 preparing mixtures of ATSP oligomer powders and fillers;   preparing a metal substrate;   curing the mixture of ATSP oligomer powders and fillers between a temperature range of 270° C. and 400° C. with the metal substrate as a backing plate to create a cured mixture;   consolidating the cured mixture in a pressure range between 0.1 MPa and 20 MPa; and   wherein the ATSP oligomer powders consist of pairs of carboxylic acid-capped and acetoxy-capped oligomers, and wherein fillers consist of discontinuous fillers and continuous fillers, and wherein the discontinuous fillers consist of milled carbon fiber, chopped carbon fiber, chopped glass fiber, milled glass fiber, ceramic powder, graphite, carbon nano tubes, graphene, and polytetrafluorethylene (PTFE) powder, and wherein the continuous fillers consist of continuous carbon fiber and continuous glass fiber, in the formats of weave sheet, unidirectional fabric sheet, unidirectional tow.   
     
     
         7 . The method of  claim 6 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by adding of ATSP oligomer powders and discontinuous fillers in a predetermined weight ratio and then blending together in a blender. 
     
     
         8 . The method of  claim 6 , wherein the metal substrate is prepared by a surface treatment, wherein the surface treatment is achieved with one of the following: particle blast roughening, dovetail shape machining, and particle (bronze) sintering. 
     
     
         9 . The method of  claim 6 , wherein the step of curing the mixture of ATSP oligomer powders includes a temperature between 270° C. and 400° C., and wherein the ATSP oligomer powders are formed by crosslinking the carboxylic acid-capped oligomer and the acetoxy-capped oligomer. 
     
     
         10 . The method of  claim 6 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by depositing of ATSP oligomer powders on continuous fillers with a solvent free method, and wherein the solvent free method consists of one of the following: dry powder bath, dry powder spray, and wet slurry. 
     
     
         11 . The method of  claim 6 , wherein the consolidation of cured mixture is achieved by setting a pressure between 0.1 MPa and 20 MPa during a temperature range of between 270° C. and 400° C. 
     
     
         12 . A method of producing aromatic thermosetting copolyester (ATSP) based composites attached with each other to form multilayer composite, comprising:
 preparing mixtures of ATSP oligomer powders and fillers;   preparing metal plates;   curing the mixture of ATSP oligomer powders and fillers between a 270° C. and 400° C. to create a cured mixture;   consolidating the cured mixture in a pressure range between 0.1 MPa and 20 MPa; and   sintering the cured mixture and metal plates together; and   wherein the ATSP oligomer powders consist of pairs of carboxylic acid-capped and acetoxy-capped oligomers, and wherein fillers consist of discontinuous fillers and continuous fillers, and wherein the discontinuous fillers consist of milled carbon fiber, chopped carbon fiber, chopped glass fiber, milled glass fiber, ceramic powder, graphite, carbon nanotubes, graphenic platelets, and polytetrafluorethylene (PTFE) powder, and wherein the continuous fillers consist of continuous carbon fiber and continuous glass fiber, in the formats of weave sheet, unidirectional fabric sheet, unidirectional tow.   
     
     
         13 . The method of  claim 12 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by adding of ATSP oligomer powders and discontinuous fillers in a predetermined weight ratios and then blending together in a blender. 
     
     
         14 . The method of  claim 12 , wherein the metal plates are prepared by surface treatment, and wherein the surface treatment is achieved with one of the following: particle blast roughening, dovetail shape machining, and particle (bronze) sintering. 
     
     
         15 . The method of  claim 12 , wherein the step of curing the mixture of ATSP oligomer powders includes a temperature between 270° C. and 400° C. and wherein the ATSP oligomer powders are formed by crosslinking the carboxylic acid-capped oligomer and the acetoxy-capped oligomer. 
     
     
         16 . The method of  claim 12 , wherein the step of preparing mixtures of ATSP oligomer powders and fillers are achieved by depositing of ATSP oligomer powders on continuous fillers with a solvent free method, and wherein the solvent free method consist of one of the following: dry powder bath, dry powder spray, and wet slurry. 
     
     
         17 . The method of  claim 12 , wherein the consolidation of cured mixture is achieved by setting a pressure of between 0.1 MPa and 20 MPa during a temperature range of between 270° C. and 400° C. 
     
     
         18 . The method of  claim 12 , wherein the sintering of the cured plates and metal plates together is achieved by setting a pressure 0.1 MPa and 20 MPa during a temperature range of 270° C. and 400° C. 
     
     
         19 . A method of producing crosslinkable polymer-based composite, comprising:
 preparing mixtures of oligomers, and fillers, ranged between 100° C. and 400° C. to create a cured mixture, and wherein the oligomers are configured to cure by a condensation mechanism and which possess moieties that are labile at an elevated temperature,   consolidating the cured mixture in a high pressure, ranged between 0.1 MPa and 20 MPa; and   wherein the crosslinkable oligomers have matched functional end-caps such that a condensation by-product is released as a consequence of their cure reaction; and wherein the fillers consist of discontinuous fillers and continuous fillers; and wherein the discontinuous fillers consist of milled carbon fiber, chopped carbon fiber, chopped glass fiber, milled glass fiber, ceramic powder, graphite, carbon nano tubes, graphene, and polytetrafluorethylene (PTFE) powder; and wherein the continuous fillers consist of continuous carbon fiber and continuous glass fiber, in the formats of weave sheet, unidirectional fabric sheet, unidirectional tow.   
     
     
         20 . A method of producing crosslinkable polymer-based composite based composites attached on metal substrate, comprising:
 preparing mixtures of crosslinkable oligomers and fillers;   preparing a metal substrate;   curing the mixture of crosslinkable oligomers and fillers between a temperature range of 100° C. and 400° C. with the metal substrate as a backing plate to create a cured mixture;   consolidating the cured mixture in a pressure range between 0.1 MPa and 20 MPa; and   wherein the crosslinkable oligomers have matched functional end-caps such that a condensation by-product is released as a consequence of their cure reaction; and wherein the fillers consist of discontinuous fillers and continuous fillers; and wherein the discontinuous fillers consist of milled carbon fiber, chopped carbon fiber, chopped glass fiber, milled glass fiber, ceramic powder, graphite, carbon nano tubes, graphene, and polytetrafluorethylene (PTFE) powder; and wherein the continuous fillers consist of continuous carbon fiber and continuous glass fiber, in the formats of weave sheet, unidirectional fabric sheet, unidirectional tow.