HIGH-RIGIDITY AND HIGH-HEAT RESISTANCE THERMOPLASTIC COMPOSITE MATERIAL COMPOSITION AND MOLDED PRODUCT MANUFACTURED THEREFROM

Abstract

The present invention relates to a thermoplastic composite composition and a molded product manufactured therefrom, and more specifically, to a high-rigidity and high-heat resistance thermoplastic composite composition and a molded product manufactured therefrom.

The thermoplastic composite composition includes: (a) a first polymer resin including a polyphenylene sulfide polymer having a melt index (ASTM D-1238, 235° C.) of 100 to 150 g/10 min; (b) a second polymer resin including a polyphenylene sulfide polymer having a melt index (ASTM D-1238, 235° C.) of 250 to 850 g/10 min, and an amorphous monomer having an aliphatic cyclobutanediol; (c) a carbon fiber surface-treated with a polyimide; (d) a fatty acid compound; and (e) a heat-resistant additive.

Since the thermoplastic composite composition according to the present invention uses the polymer resin including the amorphous monomer having the aliphatic cyclobutanediol, compatibility of the carbon fiber and the thermoplastic resin may increase, leading to an improvement in impregnation properties, so that high-rigidity and high-heat resistance aeronautical interior and a structural molded product.

Claims

1. A thermoplastic composite composition, comprising: (a) a first polymer resin including a polyphenylene sulfide polymer having a melt index (ASTM D-1238, 235° C.) of 100 to 150 g/10 min; (b) a second polymer resin including a polyphenylene sulfide polymer having a melt index (ASTM D-1238, 235° C.) of 250 to 850 g/10 min and an amorphous monomer having an aliphatic cyclobutanediol; (c) a carbon fiber surface-treated with a polyimide; (d) a fatty acid compound; and (e) a heat-resistant additive.

2. The thermoplastic composite composition of claim 1, wherein the second polymer resin comprises 70 to 80 wt % of the polyphenylene sulfide polymer and 20 to 30 wt % of the amorphous monomer having the aliphatic cyclobutanediol.

3. The thermoplastic composite composition of claim 1, wherein the amorphous monomer having the aliphatic cyclobutanediol has a specific gravity of 1.14 to 1.18 and inherent viscosity of 0.6 to 1 dL/g.

4. The thermoplastic composite composition of claim 1, wherein the carbon fiber is 800 to 1100 tex (g/km) on average.

5. The thermoplastic composite composition of claim 1, wherein 10 to 30 wt % of the first polymer resin, 10 to 25 wt % of the second polymer resin, and 50 to 79 wt % of the carbon fiber surface-treated with a polyimide, 0.5 to 2 wt % of the fatty acid compound, and 0.001 to 3 wt % of the heat-resistant additive are included based on the total amount of the thermoplastic composite composition.

6. An aeronautical interior part manufactured by the thermoplastic composite composition of claim 1.

7. A molded product for an aeronautical bracket made of the thermoplastic composite composition of claim 1.

Description

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0045] Hereinafter, the present invention will be described in more detail through examples. These examples are only for illustrating the present invention, and it will be apparent to those of ordinary skill in the art that the scope of the present invention is not to be construed as being limited by these examples.

Examples 1 to 3 and Comparative Examples 1 to 4: Preparation of Specimens Using a Thermoplastic Composite Composition

[0046] 1-1: Preparation of First Polymer Resin

[0047] A polyphenylene sulfide polymer was put in a twin-screw extruder having a screw diameter of 30 mm at 300° C., and each first polymer resin having a melt index (ASTM D-1238, 235° C.) of 150 g/10 min and 250 g/10 min was prepared.

[0048] 1-2: Preparation of Second Polymer Resin

[0049] A second polymer resin was prepared by putting a polyphenylene sulfide polymer having a melt index (ASTM D-1238, 235° C.) of 800 g/10 min and an amorphous monomer having an aliphatic cyclobutanediol having specific gravity of 1.16 and inherent viscosity of 0.6 dL/g according to a composition shown in Table 1 in a twin-screw extruder having a screw diameter of 30 mm at about 300° C.

[0050] 1-3: Preparation of UD Tape of Composite

[0051] The first polymer resin prepared in 1-1, the second polymer resin prepared in 1-2, a carbon fiber, a fatty acid compound, and a heat-resistant additive were mixed according to compositions shown in Table 1 through a screw and a barrel at 300° C. to 320° C., and then passed through a die section for impregnation, which was set at 290° C. to 350° C., preparing a UD (Unidirectional) Tape. Herein, the UD (Unidirectional) Tape was produced by setting a friction section of the carbon fiber with the polymer resins at a point 4 in order to facilitate compatibility and impregnation but a production speed at 3 to 5 m/min in order to not apply an excessive tensile force to the carbon fiber.

TABLE-US-00001 TABLE 1 First Second Carbon polymer polymer Total resin fiber resin resin Others flow index A A′ B B′ C D E F (g/10 min) Example 1 60 — 19 — 15 5 0.5 0.5 180 Example 2 60 — 19 — 13 7 0.5 0.5 175 Example 3 60 — 19 — 10 10 0.5 0.5 170 Comparative 60 — 39 — — — 0.5 0.5 150 Example 1 Comparative 60 — 19 — — 20 0.5 0.5 78 Example 2 Comparative 60 — — 19 15 5 0.5 0.5 300 Example 3 Comparative — 60 19 — 15 5 0.5 0.5 180 Example 4 A: Carbon fiber surface-treated with polyimide A′: Carbon fiber surface-treated with epoxy B: Polyphenylene sulfide polymer (melt index: 150 g/10 min) B′: Polyphenylene sulfide polymer (melt index: 250 g/10 min) C: Polyphenylene sulfide polymer (melt index: 800 g/10 min) D: Cyclobutanediol monomer E: Fatty acid compound F: Heat-resistant additive

Experimental Example 1

[0052] UD Tape (specimens) according to Examples 1 to 3 and Comparative Examples 1 to 4 were measured with respect to specific gravity, tensile strength, tensile modulus, and compressive strength, and the results are shown in Table 2.

[0053] The properties were measured in the following method.

[0054] 1-1: Measurement of Specific Gravity

[0055] Based on the standards of ASTM D 792, the specific gravity of the specimens was measured using a D-S (TOYOSEIKI, Japan) apparatus.

[0056] 1-2: Measurement of Tensile Strength

[0057] The tensile strength of the specimens was measured according to ASTM D638 by using a Model 45 (MTS, USA) device.

[0058] 1-3: Measurement of Tensile Modulus

[0059] The tensile modulus of the specimens was measured according to ASTM D638 by using a Model 45 (MTS, USA).

[0060] 1-4: Measurement of Compressive Strength

[0061] Based on the standards of ASTM D638 and using a Model 45 (MTS, USA) device, the compressive strength of the specimen was measured.

TABLE-US-00002 TABLE 2 Specific Tensile Tensile Compressive gravity strength modulus strength (g/cm.sup.3) (MPa) (GPa) (MPa) Example 1 1.57 2,150 130 1,220 Example 2 1.57 2,220 133 1,250 Example 3 1.57 2,100 131 1,198 Comparative 1.59 1,660 122 920 Example 1 Cornparative 1.53 850 65 220 Example 2 Comparative 1.57 1,825 129 1,112 Example 3 Comparative 1.57 1,350 105 912 Example 4

[0062] Referring to Table 2, Examples 1 to 3 exhibited excellent tensile strength, tensile modulus, and compressive strength, but Comparative Example 1 using no second polymer exhibited significantly deteriorated tensile strength and compressive strength, compared with Example 1.

[0063] In addition, as in Comparative Example 2, when a content of the cyclobutanediol monomer was excessively high, the cyclobutanediol monomer had an excessive influence on physical properties, and also deteriorated impregnation during the manufacturing process.

[0064] In addition, as in Comparative Example 3, as a flow index of the processed resin increased, the resin with a high flow index had an advantageous aspect in the manufacturing process but deteriorated the properties.

[0065] In addition, as shown in Comparative Example 4, when carbon fiber surface-treated not with polyimide but with epoxy was used, compatibility of the carbon fiber with a resin was deteriorated, deteriorating properties.

[0066] Referring to the aforementioned results, when a first polymer resin of a polyphenylene sulfide polymer; a second polymer resin including polyphenylene sulfide and alloyed with an aliphatic cyclobutanediol monomer to improve compatibility and impregnation; a fatty acid compound; a heat-resistant additive; and a carbon fiber surface-treated (sized) with polyimide were impregnation-processed, a composite with excellent tensile strength, tensile modulus, and compressive strength was obtained and thus may be used to manufacture an aeronautical interior and a structural molded product.

[0067] As the specific parts of the present invention have been described in detail above, for those of ordinary skill in the art, it is clear that these specific descriptions are only preferred embodiments, and the scope of the present invention is not limited thereby. Accordingly, the actual scope of the present invention will be defined by the appended claims and their equivalents.

INDUSTRIAL APPLICABILITY

[0068] Since the thermoplastic composite composition according to the present invention uses the polymer resin including the amorphous monomer having aliphatic cyclobutanediol, compatibility of the carbon fiber and the thermoplastic resin may increase, leading to an improvement in impregnation properties, so that the thermoplastic composite composition may be used to manufacture a high-rigidity and high-heat resistance aeronautical interior and structural molded product.