Self‐Reinforced melt processible polymer composites: Extrusion, compression, and injection molding

Abstract Rheological properties, extrusion, fiber spinning, compression, and injection molding of blends of polycarbonate and two thermotropic liquid crystal polymers based on wholly aromatic copolyesters have been studied. Blends were prepared using an internal Banbury mixer and static Koch mixer. Based upon differential scanning calorimetry and dynamic mechanical measurements, these blends have been shown to be incompatible in the entire range of concentrations. During extrusion and injection molding at high strain rates, it has been observed that thermotropic liquid crystal polymer at concentrations 2.5, 5, and 10 percent by weight in situ forms high modulus and high strength fibers within the polycarbonate matrix leading to self‐reinforced polymer composites. The tensile strength of the composite containing 10 percent of liquid crystal polymer exceeds that of the pure components. In addition, anisotropy of properties of the injection molded parts has been found to substantially reduce in a comparison with that of liquid crystal polymer. The processing conditions and technique for the production of self‐reinforced polymer composite during processing of the blends have been identified. This has been done by measurements of mechanical properties, direct observation of morphology, and by theoretical calculation using simplified composite theory for the unidirectional continuous fiber‐reinforced composites. At the high concentrations, 25 and 50 percent by weight, thermotropic liquid crystal polymer forms large spherical droplets inside polycarbonate leading to highly brittle material. This is in distinction from the fibrous, high modulus tough composites formed at the lower concentrations.