Continuous fiber reinforced polyarylene sulfide

摘要

A continuous fiber composite is described and methods for forming the continuous fiber composite. The continuous fiber composite includes a plurality of unidirectionally aligned continuous fibers embedded within a polyarylene sulfide polymer. The continuous fiber composite includes a very high loading of continuous fibers, for instance greater than about 40% by weight of the continuous fiber composite. The continuous fiber composite is formed by reacting a starting polyarylene sulfide with a reactively functionalized disulfide compound in a melt processing unit. Reaction between the starting polyarylene sulfide and the reactively functionalized disulfide compound leads to formation of a reactively functionalized polyarylene sulfide. Upon embedding of the continuous fibers into the reactively functionalized polyarylene sulfide, the reactivity of the polyarylene sulfide can enhance adhesion between the polyarylene sulfide polymer and the fibers.

主权项

1. A continuous fiber tape extending in a longitudinal direction, wherein the tape comprises rovings formed from continuous fibers oriented in the longitudinal direction, wherein the rovings are embedded within a polyarylene sulfide matrix, wherein the matrix includes a functionalized linear polyphenylene sulfide comprising a carboxyl functionality, wherein the functionalized linear polyphenylene sulfide has cross-linking units in an amount of no more than about 1 mol.% and is formed by melt processing a linear polyphenylene sulfide with a carboxyl functionalized disulfide compound, wherein the reactively functionalized polyphenylene polyarylene sulfide has a melt viscosity of less than about 1,500 poise as determined in accordance with ISO Test No. 11443 at a shear rate of 1200 s−1 and at a temperature of 310°C., and further wherein the continuous fiber tape.