Due to their appealing properties such as high-temperature dimensional stability, chemical resistance, compressive strength and recyclability, new-generation foams based on engineering thermoplastics such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) have been gaining significant attention. Achieving low-density foams without sacrificing the mechanical properties is of vital importance for applications in the field of transportation and construction, where sufficient compressive strength is desired. In contrast to numerous research studies on PET foams, only a limited number of studies on PBT foams and in particular, on extruded PBT foams are known. Here we present a novel route to extruded PBT foams with densities as low as 80 kg/m3 and simultaneously with improved compressive properties manufactured by a tandem reactive-extrusion process. Improved rheological properties and therefore process stability were achieved using two selected 1,3,5-benzene-trisamides (BTA1 and BTA2), which are able to form supramolecular nanofibers in the PBT melt upon cooling. With only 0.08 wt % of BTA1 and 0.02 wt % of BTA2 the normalized compressive strength was increased by 28% and 15%, respectively. This improvement is assigned to the intrinsic reinforcing effect of BTA fibers in the cell walls and struts.

The effect of plasma treatment of the multi-walled carbon nanotube (MWCNT) surface on the fracture toughness of an aerospace grade epoxy resin and its unidirectional (UD) carbon fiber prepreg laminates has attracted scientific interest. A prepreg route eliminates the possible risk of carbon nanotube filtration by unidirectional carbon fibers. X-ray photoelectron spectroscopy results suggested that oxygen atom concentration at the nanotube surface was increased from 0.9% to 3.7% after plasma modification of the carbon nanotubes. A low number (up to 0.5 wt.%) of MWCNTs was added to epoxy resin and their carbon fiber prepreg laminates. Transmission electron micrographs revealed that the plasma treatment resulted in a better dispersion and distribution of MWCNTs in the epoxy resin. Plasma-treated MWCNTs resulted in a more pronounced resistance to the crack propagation of epoxy resin. During the production of the reference and nanotube-modified prepregs, a comparable prepreg quality was achieved. Neat nanotubes agglomerated strongly in the resin-rich regions of laminates lowering the interlaminar fracture toughness under mode I and mode II loading. However, plasma-treated nanotubes were found mostly as single particles in the resin-rich regions of laminates promoting higher energy dissipation during crack propagation via a CNT pull-out mechanism.

Polyamide 66 (PA66)/poly (2,6-dimethyl-1,4-phenylene ether) (PPE) blends with a ratio of 50/50 (w/w) were produced by a twin-screw compounder. The immiscible blends were compatibilized using two different styrene–maleic anhydride copolymers (SMA) with a low (SMAlow) and a high (SMAhigh) maleic anhydride (MA) concentration of 8 and 25 wt%, respectively. Furthermore, the SMA content was varied from 0 to 10 wt%. The influence of MA concentration and SMA content on the morphological and thermomechanical properties of PA66/PPE blends was investigated. Herein, we established correlations between the interfacial activity of the SMA with blend morphology and corresponding tensile properties. A droplet-sea to co-continuous morphology transition was shown by scanning electron microscopy to occur between 1.25 and 5 wt% in the case of SMAhigh. For SMAlow, the transition started from 7.5 wt% and was still ongoing at 10 wt%. It was found that SMAlow with 10 wt% content enhanced the tensile strength (10%) and elongation at break (70%) of PA66/PPE blends. This improvement can be explained by the strong interfacial interaction of SMAlow within the blend system, which features the formation of nanoemulsion morphology, as shown by transmission electron microscopy. Very small interdomain distances hinder matrix deformations, which forces debonding and cohesive failure of the PPE phase as a “weaker” main deformation mechanism. Due to a lack of interfacial activity, the mechanical properties of the blends with SMAhigh were not improved.

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