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Recent Development in Thermoplastic Composites: A Review of Matrix Systems and Processing Methods

E. I. du Pont de Nemours and Company, Inc. Composites Centers Chestnut Run Plaza 702 Wilmington, Delaware 19880-0702

J.K. Lees

E. I. du Pont de Nemours and Company, Inc. Composites Centers Chestnut Run Plaza 702 Wilmington, Delaware 19880-0702

Manufacturers of composite materials have been developing high strength fiber rein forced composites with thermoplastic matrix systems exhibiting enhanced performance in fracture toughness and damage tolerance with the potential of reduced manufacturing cost for both primary and secondary structure components. A review will be made of principal thermoplastic matrix systems and processing methods used to fabricate the fiber rein forced composites, which have been developed during recent years. Included is a com parison of the neat matrix resins' chemical structure, thermal/tensile properties, fracture toughness, melt viscosity, solvent resistance, morphology and melt processability. The matrix-dominated mechanical properties of thermoplastic composites are given, including flexural, short beam shear and compression strengths, interlaminar fracture toughness and/or compression-after-impact performance. Innovative process development in thermoplastic composites including thermoformable sheets, filament winding, 3D braid ing and impregnation will also be reviewed and discussed.

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