This technology is available from Temarex Corporation.

LIQUID CRYSTAL POLYMER COMPOSITES

Title:SELF-REINFORCED COMPOSITE AND PROCESS FOR PREPARING SAME

Inventor(s):A. Isayev

Disclosure 167 U.S. Patent 5,260,380

A self-reinforced polymer composite in the form of a non-laminated shaped article is prepared by (a) melt blending (1) a matrix polymer which is a melt processable flexible chain polymer or first liquid crystal polymer (LCP) and (2) a fiber forming melt processable second LCP under high strain mixing conditions inducing fiber formation,cooling and stretching the resulting blend, and (b) shaping the resulting blend by injection molding or extrusion at a temperature which is above the minimum melt processing temperature of the matrix polymer but below that of the fiber forming second LCP.By shaping at a temperature below the minimum processing temperature of the fiber-forming LCP, the fiber structure formed during cooling is preserved. The resulting shaped articles have outstanding mechanical properties,e.g., tensile strength, modulus and impact strength.

Title:SELF REINFORCED THERMOPLASTIC COMPOSITE LAMINATE

Inventor(s):A. Isayev

Disclosure 163 U.S. Patent 5,268,225 Disclosure 163-DIV U.S. Patent 5,238,638

Composite laminates are prepared from thin sheets of thermotropic liquid crystal polymer blends.A preferred blend contains 2 thermotropic liquid crystal polymers i.e., a first liquid crystal polymer in LCP-1, and a second liquid crystal polymer (LCP-2), the second liquid crystal polymer having a higher melting point than the first.The second liquid crystal polymer is molecularly oriented and is preferably at least partially in the form of microscopic fibers in a matrix of the first liquid crystal polymer.The two liquid crystal polymers are phase separated in the solid phase and have overlapping melt processing temperatures.

The laminates may be formed so that the direction of molecular orientation is either the same in all layers or different in successive layers.The blends give composites having mechanical properties, e.g., tensile strength and secant modulus, which are as good or nearly as good (and in some cases better than) those of either pure LCP, at substantially lower cost.The process of this invention saves energy than those processes required to form otherwise similar laminates containing preformed reinforced fibers.

This technology is ideally suited for automotive (i.e. bodies),aircraft and marine (i.e. hulls) industries.In general, composites of this invention are useful in making articles or parts where high tensile strength, high modulus and/or high impact strength are advantageous, particularly where reasons of weight reduction it is desirable to use reinforced plastic instead of metal.

Title:SELF REINFORCED COMPOSITE OF THERMOTROPIC LIQUID CRYSTAL POLYMERS

Inventor(s):A. Isayev, P. Subramanian

Disclosure 144 U.S. Patent 5,070,157

Blend of two or more Thermotropic liquid crystal polymers and process for preparing same.Blends of this invention contain at least two, preferably only two, Thermotropic liquid crystal polymers which are melt processable.These liquid crystal polymers are wholly aromatic polyesters.At least two polymers in the blend are processable in the melt phase and phase separated in the solid phase.Solid reinforcing agents may be present, but are not necessary and, in any case, must be in the solid phase at temperatures at which the blend is melt processable.Products of this invention are formed in the melt phase under high strain conditions.

Products of the present invention exhibit exceptional mechanical properties,including tensile modulus, tensile strength and notched Iodo impact strength; high heat resistance and good electrical properties which remain stable over a wide range of temperatures and frequencies.Polymer composites may be pelletized and then formed into shaped articles, tapes, films or fibers.Polymer composites of this invention are especially suitable for injection molding.

Composites of this invention have tensile strength comparable to those of steel on a volume basis, and to have strengths exceeding those of aluminum on a volume basis.On a weight basis, the composite materials of this invention are much stronger than either steel or aluminum since the density of the new materials is about 1.4 versus about 2.7-2.8 for aluminum and approximately 7.5 for steel.This means that the novel polymer composites of blends give light weight strong materials.

This technology is ideally suited for high performance applications such as electrical, electronics, aerospace and automotive.Potential applications include: automotive - fuel lines and tanks, body panels, struts, under-the-hood parts, engine parts, under-the-hood electronics; aerospace - luggage compartment panels, floors, seat structures, bulk heads, helicopter blades, solar concentrators, solar panels; electronics and opticals - optical fiber jackets, interconnect devices, circuit boards, interlayer dielectrics, wire insulation, substrates for electronic packaging; marine - boat hulls and interior panels; medical - barrier film for packaging.

In addition, polymer composites are useful as replacements for present composite components which are produced by sheet molding compound (SMC) technology.Products of this invention can be produced at faster rates and with less power consumption, resulting in lower product costs, compared to conventional composites in which fibers are prepared in advance.

Title:THERMOPLASTIC WEB AND PROCESS FOR MANUFACTURING SAME

Inventor(s):A. Isayev, P. Subramanian

Disclosure 125 U.S. Patent 5,032,433

An openwork web of a polymer blend of a thermoplastic base or matrix polymer and a Thermotropic liquid crystal polymer (LCP) is formed by preparing a melt blend of the base polymer and a LCP; continuously extruding a continuous web of said blend under melt conditions; allowing the web to cool as it passes over a succession of rolls, including a pair of knit rolls which are driven at a speed faster than the speed at which the web is formed, so that the web is stretched or drawn and converted from a continuous web into an openwork web comprising polymer blend fibers with interstices between the fibers.It is believed that these polymer blend fibers comprise microscopic fibers of the LCP in a matrix of the base polymer.Suitable matrix polymers include conventional thermoplastic material such as PE, PP, EPM, PS, PVC, PA, PET, PEEK, PPS, PEI, PBT, and PC.

Two advantages over the prior art.First, the webs are formed without a blowing agent and secondly, webs are self-reinforced due to the presence of high performance microscopic fibers of a Thermotropic LCP.This leads to strong products and low cost operations.

The products of this invention are suitable for various purposes, particularly where strong materials having a net-like configuration are required.A major application of the products and processes of this invention is in the packaging industry. Products of this invention can also be used as fishing nets and as nets for other purposes where it is necessary to support heavy loads.The high impact strength in a direction transverse to the web is also useful in various applications.It is possible to tailor make products in any desired width, to fuse the edges of two or more webs together, and to control the density of the web.

Title:SELF REINFORCED THERMOPLASTIC COMPOSITE LAMINATE

Inventor(s):A. Isayev

Disclosure 123 U.S. Patent 5,275,877

A shaped, reinforced thermoplastic composite, such as composite laminate, comprising a thermoplastic matrix polymer and a plurality of long fibers of a liquid crystal polymer (LCP) which is formed in situ in the matrix polymer.This composite is made by forming a prepreg as a plurality of individual sheets or layers each of which comprises long, essentially unidirectionally oriented fibers of said LCP in a thermoplastic polymer matrix.A lay-up is formed by cutting each individual sheet or layer into pieces so that the direction of fiber orientation in each such piece is either parallel to one pair of edges or at a 45 degree angle to all of the edges.The lay-up is shaped under heat and pressure to form the composite.

This technology is ideally suited for automotive (i.e. bodies), aircraft and marine (i.e. boat hulls) industries, as well as other uses apparent to those skilled in the art.

Title:WHOLLY AROMATIC POLYESTER FIBER-REINFORCED HIGH PERFORMANCE THERMOPLASTIC AND PROCESS FOR PREPARING SAME

Inventor(s):A. Isayev

Disclosure 113 U.S. Patent 5,006,402 Disclosure 113-CIP U.S. Patent 5,006,403

Self-reinforced polymer composites of 60-5% by weight of an at least partially crystalline high performance thermoplastic polymer and 40-95% by weight of a melt processable wholly aromatic polyester which exhibit anisotropic properties in the melt phase.This wholly aromatic polyester is a liquid crystal polymer, or LCP.The high performance thermoplastic polymer has a melting point of at least 200oC.Polyether etherketone is a preferred, at least partially crystalline, polymer.The wholly aromatic polyester is in the form of predominantly unidirectionally oriented continuous fibers, primarily in the range of about 1 to 10 micrometers in diameter, distributed in a matrix of polyether etherketone.

The polymer composites of this invention have high tensile strength, high modulus, satisfactory elongation, good impact strength, good flame resistance, good high temperature properties, and good electrical properties which remain stable over a wide range of temperatures and frequencies.Suitable base polymers include conventional thermoplastic material such as PS, PA, PC, PEI, PEEK, PPO, PPS, PMP and PBT.

This technology is ideally suited for high performance applications such as electrical, electronics, aerospace, automotive, marine and medical.Potential applications include: automotive - fuel lines and tanks, body panels, struts, under-the-hood parts, engine parts, under-the-hood electronics; aerospace - luggage compartment panels, floors, seat structures, bulk heads, helicopter blades, solar concentrators, solar panels; electronics and opticals - optical fiber jackets, interconnect devices, circuit boards, interlayer dielectrics, wire insulation, substrates for electronic packaging; marine - boat hulls and interior panels; medical - barrier film for packaging.

In addition, polymer composites are useful as replacements for present composite components which are produced by sheet molding compound (SMC) technology.Products of this invention can be produced at faster rates and with less power consumption, resulting in lower product costs, compared to conventional composites in which fibers are prepared in advance.

Title:COMPOSITE THERMOPLASTIC ELASTOMER BLEND AND PROCESS FOR PREPARING THE SAME

Inventor(s):A. Isayev

Disclosure 103 U.S. Patent 5,021,475

Thermoplastic elastomer blends comprising a thermoplastic elastomer and 1-20% by weight of a water insoluble alkyl cellulose which exhibits improved mechanical properties compared to the unblended thermoplastic elastomer.The preferred thermoplastic elastomer is a blend of polypropylene and EPDM.The preferred alkyl cellulose is ethylcellulose, and preferred concentrations are 2.5-15%, most preferably 5-12%, all percentages being by weight based on total polymer content.The blends are formed by high shear mixing at a temperature at which both materials are melt processable. The alkyl cellulose in the product is present as domains which are essentially uniformly dispersed in a thermoplastic elastomer matrix.

In general, polymer composites of this invention may be used for the same purposes as other fiber-reinforced polymer composites having the same base polymer.

Title:WHOLLY AROMATIC POLYESTER FIBER-REINFORCED POLYETHERIMIDE COMPOSITE AND PROCESS FOR PREPARING SAME

Inventor(s):A. Isayev, S. Swaminathan

Disclosure 95 U.S. Patent 4,835,047

Novel, self-reinforced polymer composites of polyetherimide and a melt processable wholly aromatic polyester are prepared.The wholly aromatic polyester exhibits anisotropic properties in the melt phase.Mixing is carried out at a temperature at which both the polyetherimide and the wholly aromatic polyester are melt processable.The products comprise about 35-95% by weight of wholly aromatic polyester, in the form of predominantly unidirectionally oriented continuous fibers, primarily in the range of about 1 to 10 micrometers in diameter, distributed in a matrix of polyetherimide.

The polymer composites of this invention have high tensile strength, high modulus, satisfactory elongation, good impact strength and good high temperature properties.

This technology is ideally suited for high performance applications such as electrical, electronics, aerospace, automotive, marine and medical.Potential applications include: automotive - fuel lines and tanks, body panels, struts, under-the-hood parts, engine parts, under-the-hood electronics; aerospace - luggage compartment panels, floors, seat structures, bulk heads.

Other potential applications include: helicopter blades, solar concentrators, solar panels; electronics and opticals - optical fiber jackets, interconnect devices, circuit boards, interlayer dielectrics, wire insulation, substrates for electronic packaging; marine - boat hulls and interior panels; medical - barrier film for packaging.

In addition, polymer composites are useful as replacements for present composite components which are produced by sheet molding compound (SMC) technology.Products of this invention can be produced at faster rates and with less power consumption, resulting in lower product costs, compared to conventional composites in which fibers are prepared in advance.

Title:LIQUID CRYSTAL FIBER-REINFORCED POLYMER COMPOSITE AND PROCESS FOR PREPARING SAME

Inventor(s):A. Isayev, M. Modic

Disclosure 76-CIP U.S. Patent 4,728,698

Novel self-reinforced polymer composites of a base polymer with a melt processable liquid crystal polymer are prepared. The base polymer is a flexible chain polymer, e.g. a conventional thermoplastic. Polycarbonate is a particularly suitable base polymer. The liquid crystal polymer is melt processable, that is, it has a melting point and exhibits anisotropic properties in the melt phase.Wholly aromatic copolyesters are particularly suitable. Mixing is carried out at a temperature at which both the base polymer and liquid crystal are melt processable (i.e., at a temperature at which the base polymer flows readily and the liquid crystal polymer is above its melting point).

The products of this invention comprise about 2-20% by weight of liquid crystal polymer, in the form of essentially unidirectionally oriented continuous fibers, primarily in the range of about 1 to 10 micrometers in diameter, distributed in a matrix of the base polymer.Suitable matrix polymers (comprised by weight from about 80-98%) include conventional thermoplastic material such as PE, PP, EPM, PS, PVC, PA, PET, PEEK, PPS, PEI, PBT, and PC.

The polymer composites of this invention have high tensile strength in both the fiber direction and the transverse direction, and have high modulus, satisfactory elongation, good impact strength and good high temperature properties.

This technology is ideally suited for high performance applications such as electrical, electronics, aerospace, automotive, marine and medical where increased performance of the matrix polymer is desired.This technology due to the blending ratio is excellent for price sensitive products requiring increased performance.