Does a Compatibilizer Enhance the Properties of Carbon Fiber-Reinforced Composites?

Abstract

We have evaluated the effectiveness of compatibilizers in blends and composites produced using a solvent manufacturing process. The compatibilizers were two different types of polyethylene (linear low-density and high-density) grafted with maleic anhydride (MAH) and a highly functionalized, epoxy-based compatibilizer with the tradename Joncryl. The selected material combinations were an ultra-high-molecular-weight polyethylene (UHMWPE) with MAH-based materials as compatibilizers and a polyphenylene sulfide plus polytetrafluoroethylene (PPS-PTFE) polymer blend with an epoxy-based compatibilizer. The findings revealed that while the compatibilizers consistently enhanced the properties, such as the impact strength and hardness of PPS-based compositions, their utility is constrained to less complex compositions, such as fibrous-reinforced PPS or PPS-PTFE polymer blends. For fibrous-reinforced PPS-PTFE composites, the improvement in performance does not justify the presence of compatibilizers. In contrast, for UHMWPE compositions, compatibilizers demonstrated negligible or even detrimental effects, particularly in reinforced UHMWPE. Overall, the epoxy-based compatibilizer Joncryl stands out as the only effective option for enhancing mechanical performance. Thermal and chemical characterization indicated that the compatibilizers function as chain extenders and enhance the fiber–matrix interface in PPS-based compositions, while they remain inactive in UHMWPE-based compositions. Ultimately, the incompatibility of the compatibilizers with certain aspects of the manufacturing method and the inconsistent integration with the polymer are the main reasons for their ineffectiveness in UHMWPE compositions.