Reinforced plastic continued thermosets

Glass fibres dominate this field either as long continuous fibres (several centimetres long), which are hand-laid with the thermoset precursors, e.g., phenolics, epoxy, polyester, styrenics, and finally cured (often called fibre glass reinforcement plastic or polymer (FRP)). With thermoplastic polymers, e.g., PP, short fibres (less than 1 mm) are used. During processing with an extruder, these short fibres orient in the extrusion/draw direction giving anisotropic behaviour (properties perpendicular to the fibre direction are weaker). 

During the 1940s the Society of the Plastics Industry started the Low Pressure Industries Division, which shortly thereafter became the Reinforced Plastics Division under the direction of Charlie Condit and in 1954, with D. V. Rosato s leadership, the Reinforced Plastics/Com-posite Division. It is currently called the Composites Institute. The original product was glass-fiber-thermoset polyester plastic RPs. To date about 90wt% of all RPs continue to be glass-fiber-TS polyester plastics. 

The terms reinforced plastics (RP) and composites refer to combinations of plastic materials and reinforcing materials, usually in fiber form (chopped fibers, porous mats, woven fabrics, continuous fibers, etc. see Fig. 7-1). Both thermoset (TS) and thermoplastic (TP) resins are used. When modern RP industry started in 1940, glass-fiber-reinforced unsaturated polyester (TS), low pressure or contact pressure, curing resins were used. Today about 60 percent of the plastics industry uses many different forms of glass fiber-polyester composites. In this chapter the abbreviation RP will be used, and in references to polyester resin it will refer only to TS, as relatively little TP polyester is used in RPs. 

Clear polyester sheet stock and rods are available13 and, like reinforced polyester plastic, may be drilled, sawed, and machined. This clear plasic is harder than poly(methyl methacrylate) and much more solvent resistant than either po-lyfmethyl methacrylate) or polystyrene. As with all thermosetting plastics, it may not be heat-formed or solvent-bonded. However, bonding with epoxy cements is satisfactory. This plastic is claimed to give continuous service at 80°C and intermittent service up to 150°C. 

Research on the pyrolysis of thermoset plastics is less common than thermoplastic pyrolysis research. Thermosets are most often used in composite materials which contain many different components, mainly fibre reinforcement, fillers and the thermoset or polymer, which is the matrix or continuous phase. There has been interest in the application of the technology of pyrolysis to recycle composite plastics [25, 26]. Product yields of gas, oil/wax and char are complicated and misleading because of the wide variety of formulations used in the production of the composite. For example, a high amount of filler and fibre reinforcement results in a high solid residue and inevitably a reduced gas and oiFwax yield. Similarly, in many cases, the polymeric resin is a mixture of different thermosets and thermoplastics and for real-world samples, the formulation is proprietary information. Table 11.4 shows the product yield for the pyrolysis of polyurethane, polyester, polyamide and polycarbonate in a fluidized-bed pyrolysis reactor [9]. 

All TP or TS matrix property can be improved or changed to meet varying requirements by using reinforcements. Typical thermoplastics used include TP polyesters, polyethylenes (PEs), nylons (polyamides/ PAs), polycarbonates (PCs), TP polyurethanes (PURs), acrylics (PMMAs), acetals (polyoxymethylenes/POMs), polypropylenes (PPs), acrylonitrile butadienes (ABSs), and fluorinated ethylene propylenes (FEPs). The thermoset plastics include TS polyesters (unsaturated polyesters), epoxies (EPs), TS polyurethanes (PURs), diallyl phthalates (DAPs), phenolics (phenol formaldehydes/PFs), silicones (Sis), and melamine formaldehydes (MFs). RTSs predominate for the high performance applications with RTFs fabricating more products. The RTPs continue to expand in the electronic, automotive, aircraft, underground pipe, appliance, camera, and many other products. 

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