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SPONSOR/MONITOR'S REPORT NUMBER(S)Not Applicable processes have been successfully developed to enable infusion of thermoplastic prepolymers into glass and carbon fiber performs at temperatures up to 210°C. The prepolymers used in this study were CBT (Cyclic Butylene Teraphthalate oligomer)
DISTRIBUTION / AVAILABILITY STATEMENTleading to a PBT composite, APLC-12 (Anionically-Polymerised Lactam -12) leading to a PA-12 composite, and APLC-6 (Anionically-Polymerised Lactam -6) leading to a PA-6 composite. Mixtures of PA-12 and PA-6 were also examined.Traditionally it has not been easy to mold thermoplastic-reinforced composites due to their high viscosities. High temperatures and pressures were always required to fully impregnate fiber beds. Liquid composite molding processes, such as those demonstrated in this report, were virtually impossible. The employment of an activated pre-polymer melts eliminates the problems associated with high viscosity.All of the materials processed here were using vacuum pressure only.For the CBT pre-polymer, a flat heated VARTM mold was used, together with a heated delivery system for transporting the molten resin from the melting unit to the mold. The fiber perform was bagged with a high temperature plastic film and sealing tape. The CBT pre-polymer (supplied by Cyclics Corporation), was melted by heating to 165°C. A catalyst was added just prior to infusion of the catalysed prepolymer into the fiber bed. The viscosity-time characteristics for this material, which polymerized within the mold to form polybutylene terephthalate (PBT), were measured to establish the VARTM processing window. Viscosity values for this material at 160°C varied from 0.1Pa.secs at introduction of the catalyst to 0.5Pa.secs GPa at room temperature to 9 GPa at 150°C for the S2 glass fabric/PBT composite.For the carbon fabric panels, flexural modulii up to 51 GPa were achieved, with flexural strengths of up to 450 MPa.For the PA-12 and PA-6 pre-polymers, a rigid, electrically heated RTM mold was developed. A commercially-available anionic polymerization activator (Grinolit proved to be a quic...