# Patent

## Title
Method of preparing a composite with disperse long fibers and nanoparticles

## Abstract

A composite material having polymeric resin with disperse phases of reinforcing fibers and nanoparticle materials and its manufacture is disclosed herein. The nanoparticles may be bound together and added to the polymeric resin as microscale aggregations, and then unbound to create a disperse phase of nanoparticles in the resin. In other embodiments, the nanoparticles may be bound to a substrate, such as long fibers, and added to a polymeric resin. The nanoparticles are then unbound from the substrate and dispersed throughout the polymeric resin. The polymeric resin may have multiple components where one component may control the dispersion of the nanoparticles.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
This is a non-provisional of U.S. Application No. 60/727,723, filed Oct. 18, 2005, which is incorporated herein by reference.


TECHNICAL FIELD
The invention relates generally to plastics reinforced with a combination of long fibers and nanoparticles. More particularly, the invention relates to improvements in the known technology for controlling the dispersion of the nanoparticles in the continuous polymer matrix.
BACKGROUND OF THE INVENTION
Among the various thermoset polymers, epoxy resins provide superior overall performance, such as good mechanical properties, chemical resistance, and low shrinkage. Therefore, epoxy resins are high-performance systems for use in coating, adhesive, civil engineering, structural, electronic and composite applications.
In 1907, phenolic resins were the first thermoset resins to be synthesized commercially. These resins have excellent fire performance, good dimensional stability, excellent thermal insulation properties, and are cost effective. These properties enable phenolics to be used in household appliances, business equipment, wiring devices, automotive electrical systems, and mass transit.
Fiber reinforced plastics (FRPs) are the most widely used composites. In general, fibers are the principal load-carrying members, while the surrounding plastic matrix keeps the fibers in the desired location and orientation, acting as a load transfer medium. The plastic also protects the fibers from environmental damage due to exposure to elevated temperature and humidity. Fiber-reinforced composites have low specific gravity, high internal damping, and high strength-to-weight ratio and modulus-to-weight ratio. There have been numerous applications for FRPs, and additional applications are continually sought, due to the attractive properties. In the FRP art, the terms “long fiber” and “short fiber” are commonly used to designate fibers and will be understood by those of skill in the art.
A “nanocomposite” is a composite containing a disperse material with at least one dimension that is smaller than about 100 nm in size. Due to the nanoscale dispersion and the high aspect ratios of the inorganic clays, polymer-layered silicate nanocomposites (PLSNs) exhibit light weight, dimensional stability, heat resistance, and a certain degree of stiffness, barrier properties, improved toughness and strength with far less reinforcement loading than conventional composite counterparts. The synthesis and characterization of PLSNs has become one of the frontiers in materials science.
Since the discovery of carbon nanotubes (CNTs), many people have studied the properties of polymer-carbon nanotube composites. However, the high cost and low volume of production of the CNT have greatly limited product development and application. Carbon nanofibers (CNF), defined as carbon fibers with diameters of up to 200 nm (and typically in the 100-200 nm range) and lengths of up to about 100 microns, may serve as a substitute for the carbon nanotubes. Recent studies indicate that polymer-carbon nanofiber composites (PCNFCs) have properties similar to polymer-carbon nanotube composites. These CNF nanocomposites can be used to make conductive paints, coatings, films, tubes, sheets, and parts for electrostatic painting, electro-magnetic interference and electro-static discharge applications. In addition, these composites also provide improved strength, stiffness, dimensional stability and thermal conductivity. It makes the PCNFCs a very promising material for a wide range of applications in automotive, aerospace, electronic and chemical industries.
Although fiber-reinforced plastics (FRP) have good mechanical properties, an interface exists between the polymer matrix and the individual fibers. This interface, which represents a substantial area, is subject to diffusive attack by water and other small molecules. This can cause a substantial drop in interfacial strength and failure of adhesion between the components. Under tension, compression, shear, or impact, failure of the polymer matrix may also take place.
A problem continually encountered in preparing nanocomposites has been the difficulty in properly dispersing the nanoparticles in the continuous polymer phase. For example, it is often difficult to load more than about 10 weight % of nanoparticles into the continuous phase. By way of comparison, a highly-loaded FRP can often contain greater than 50 weight % of the disperse fiber phase. Not unexpectedly, the enhancement of mechanical properties of the continuous phase polymer in a typical PLSN or PCNFC is relatively low compared with the enhancement of mechanical properties in a typical FRP. When this is combined with the high cost of the nano-scale material, it would be surprising if nanocomposites would have already made significant market penetration.
It is therefore an object of the present invention to provide a composite material that effectively combines advantages of a disperse fiber phase and a disperse nanoparticle phase.
SUMMARY OF THE INVENTION
This and other objects are achieved by the exemplary embodiments presented in more detail below.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood through reference to the exemplary embodiments disclosed herein, wherein identical parts are identified by identical part numbers, and wherein:
FIG. 1 is an x-ray diffraction pattern showing the effects of adding poly(vinyl acetate) to composites containing long fibers and nanoclays in a continuous phase of unsaturated polyester resin;
FIGS. 2A, 2B are microphotographs of an unsaturated polyester—nanoclay—long fiber composite material, FIG. 2B being an enlargement of a portion of FIG. 2A;
FIG. 3 is a diagram showing the improved flexural modulus obtained by adding poly(vinyl acetate) to an unsaturated polyester—nanoclay—long fiber composite material;
FIG. 4 is a scanning electron microscope image of a phenolic resin—carbon nanofiber—long glass fiber composite.



DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
In an exemplary embodiment of the invention, the advantages of both FRP and polymer nanocomposites are combined to produce a composite having previously unexpected properties. The composite has a substantially continuous matrix of a polymer, especially a polymer resin, such as an epoxy or a phenolic resin. Two distinct disperse phases are present in a substantially uniform manner in the matrix. The first disperse phase comprises reinforcing fibers, such as are commercially available and are manufactured from glass, carbon or aramid. The second disperse phase comprises nanoclays, carbon nanofibers or carbon nanotubes. As described in more detail below, the polymer matrix will generally comprise a predominant amount of a first, generally hydrophobic, component and an effective amount of a second component, the second component selected to moderate the hydrophobicity of the first component.
Speaking generally, reinforcing fibers, especially long glass or carbon fibers embue the composite with good mechanical properties. Between glass and carbon fibers, the glass fibers are more hydrophilic. The nanoparticles improve the barrier properties and strengthen the matrix between long fibers in order to reduce the matrix failure in the composites and extend the longevity of the composites. Between nanoclays and carbon nanofibers, the nanoclays are more hydrophilic.
To succeed in producing these new composites, two questions need to be answered. How to well disperse nanoparticles into FRPs and whether the resin processability can be maintained with the presence of nanoparticles? Speaking generally, phenolic resins or unsaturated polyester (UP) resins containing poly(vinyl acetate) (PVAc) as a low profile additive are of higher hydrophilicity than the epoxy resins or unsaturated polyester resins lacking the poly(vinyl acetate). Therefore, a variety of combination of these different materials may be selected to control the distribution and dispersion of nanoparticles in the FRP to achieve desirable composite properties and processability.
In an exemplary scheme, raw nanoclay is dispersed easily into the phenolic resin, so a phenolic-clay nanocomposite is synthesized. Then, reinforcing fibers of long glass or carbon fibers are integrated into the phenolic-clay nanocomposite. This step, producing a hybrid composite can be achieved using a known prepreging or resin transfer molding (RTM) process. The hybrid composite obtained has long carbon fibers reinforcing a phenolic matrix having well-dispersed nanoclay. Since the added nanoparticles tend to increase the resin viscosity, especially when good dispersion is achieved at a high loading level of the nanoclay, resin processing may become quite difficult in preparing prepregs for autoclave molding or in RTM mold filling. If the nanoclay dispersion is controlled to initially limit the amount of dispersion, the resin viscosity may remain low enough to facilitate prepreg preparation or RTM mold filling. In such a system, the nanoclays form micro-scale aggregates that are not well dispersed by a binder. After molding, many techniques are useful to exfoliate the nanoclay aggregates. Among these techniques are: elevated temperature to melt the binder, ultrasonic energy, or a combination of both. Ultrasonic energy is also useful in improving the prepreg consolidation. This extra advantage may further improve the product properties.
In a further exemplary scheme, the same approach can be applied to organoclays or CNFs in epoxy resins. In such an instance, the nanoparticles, such as a CNF, are bound to the reinforcing fiber surface, such as a glass surface. After this, a pure resin, such as epoxy, is integrated with the reinforcing fibers though the known prepreg formation or RTM mold filling process, essentially ignoring the presence of the CNF on the reinforcing fiber surface. When curing the composites at elevated temperatures, the binder between the CNF and the reinforcing fibers would melt, with the CNFs diffusing from the reinforcing fiber surface into the epoxy matrix. This is because the CNFs and epoxy resins are hydrophobic, while the glass surface is hydrophilic, so the CNF prefers to diffuse into the more compatible epoxy matrix. This second method has the advantage of using a composite manufacturing process, including prepregs preparation and molding, that is the same as that without any nanoparticles. However, the nanoparticles have to be much more compatible with the matrix resin than with the reinforcing fibers to effect good dispersion. Again, nanoparticle dispersion in the polymer matrix may be enhanced by applying ultrasonic energy.
This second approach is also applicable to a system comprising long carbon fibers and raw clays with more hydrophilic resins, such as phenolics. Mechanical and thermal properties of such composites will be compared with both long fiber-reinforced composites and polymer nanocomposites. Material composition, binder selection, and processing conditions will be optimized to achieve the best properties of the hybrid composites. Rheological measurements, kinetic analysis, permeability measurements, and mold filling observations for resins containing nanoparticles will be carried out to quantify the composite processability during molding and curing. XRD, SEM, and TEM characterizations will also be performed to determine the nanoparticle dispersion in the molded composites.
Attention is now directed to FIG. 1, which presents x-ray diffraction studies of two different systems incorporating the aspects of one of the inventive embodiments. Four distinct traces are illustrated in FIG. 1. In both cases, the polymeric matrix is an unsaturated polyester (“UP”). In the first case, shown as line 12, glass fibers coated with a nanoclay are dispersed in the UP, in the absence of poly(vinyl acetate). The expected diffraction peak for the clay (in the zone between 2 and 3 on the abscissa) is not seen in line 12, indicating that the nanoclay has stayed at the glass fiber surface and has not dispersed into the UP matrix. When the identical system is prepared again, but the polymeric matrix includes 3.5% PVAc, line 16 is obtained, showing the diffraction peak indicative of diffusion of the nanoclay into the polymeric matrix. In a second case, shown as line 14, carbon fibers are coated with the nanoclay and dispersed in the UP, in the absence of poly(vinyl acetate). The expected diffraction peak for the clay is not seen in line 14, indicating that the nanoclay has stayed at the carbon fiber surface and has not dispersed into the UP matrix. When the identical system is prepared again, but the polymeric matrix includes 3.5% PVAc, line 18 is obtained, showing the diffraction peak indicative of diffusion of the nanoclay into the polymeric matrix.
Further confirmation of this phenomenon is provided in FIGS. 2A and 2B. A photomicrograph of the type of system shown in line 12 of FIG. 1 is presented, with a glass fiber visible near the bottom of FIG. 2A. A bar at the top of FIG. 2A, indicating a length of 3.2 microns, shows the scale of the image. FIG. 2B, which is enlarged from the image of FIG. 2A at the point shown near the glass fiber, demonstrates that the nanoclay particles have stayed near the glass fiber. In FIG. 2B, the bar shows a length of 160 nm, to illustrate scale. This shows that the absence of PVAc in this system may improve the barrier properties of the material, by preventing small molecules, such as water, from diffusing into an interface between the long fibers (glass, in this example) and the polymeric matrix.
Some further aspects of the UP-glass fiber—nanoclay system are shown in FIG. 3. In a system without nanoclay being present (bars 22 and 24 in FIG. 3), addition of 3.5% PVAc to the system has little effect on the flexural modulus, and, if anything, the flexural modulus is reduced slightly. When clay is added (bars 26 and 28 in FIG. 3), the presence of PVAc markedly improves the flexural modulus, as seen by comparing bars 26 and 28. Comparing systems with or without nanoclay, that is, comparing bar 22 to bar 26 or comparing bar 24 to bar 28, it is readily noted that the presence of nanoclay makes little difference when PVAc is absent, but the addition of nanoclay greatly improves flexural modulus when the PVAc is present in the UP polymer matrix.
In another example, a system involving phenolic resin with disperse carbon nanofibers and long glass fibers is demonstrated by way of a scanning electron micrograph presented as FIG. 4. In this system, where a pair of the long glass fibers are shown by arrows, the carbon nanofibers are seen to be well dispersed into the phenolic matrix that acts as the continuous phase.
Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification and examples should be considered exemplary only and do not limit the intended scope of the invention.

## Claims

1. A method of preparing a composite material including nanoparticles and fibers dispersed in a resin, comprising the steps of:
binding nanoparticles to said fibers;
adding said fibers having said bound nanoparticles thereon to said resin; and
unbinding said nanoparticles from said fibers so as to disperse said nanoparticles in said resin.

2. The method of claim 1 wherein said nanoparticles are more compatible with said resin then said fibers.

3. The method of claim 1 wherein said nanoparticles and said resin are hydrophobic.

4. The method of claim 1 wherein said fibers are hydrophilic.

5. The method of claim 1 wherein the unbinding of said nanoparticles from said fibers occurs during curing of said composite.

6. The method of claim 1 wherein said addition of said fibers having said bound nanoparticles is integrated with said resin through the use of pre-impregnation formation.

7. The method of claim 1 wherein said addition of said fibers having said bound nanoparticles is integrated with said resin through the use of resin transfer molding.

8. The method of claim 1 wherein said fibers are reinforcing fibers selected from the group consisting of glass, carbon, aramid, and combinations thereof.

9. The method of claim 1 wherein said nanoparticles are selected from the group consisting of nanoclays, carbon nanofiber, carbon nanotubes, and combinations thereof.

10. The method of claim 1 further comprising applying ultrasonic energy to increase dispersion of said nanoparticles.

11. The method of claim 1 wherein said resin comprises an effective amount of a polymer to selectively control dispersion of said nanoparticles in said resin.

12. A method of preparing a composite material including nanoparticles and fibers dispersed in a resin, comprising the steps of:
providing a resin, wherein said resin includes poly(vinyl acetate);
binding said nanoparticles to said fibers;
adding said fibers having said bound nanoparticles thereon to said resin; and
unbinding said nanoparticles from said fibers so as to disperse said nanoparticles in said resin.

13. The method of claim 12 wherein poly(vinyl acetate) is present at about 3.5% by weight of said resin.

14. The method of claim 12 wherein said nanoparticles are more compatible with said resin than said fibers.