Thermoplastic composites based on
thermotropic liquid crystalline
polymer (LCP) materials are interesting candidates for reinforced
composite application due to their promising mechanical performance
and potential for recyclability. In combination with a societal push
toward the more sustainable use of materials, these properties warrant
new interest in this class of composites. Though numerous studies
have been performed in the past, a coherent set of design rules for
LCP design for the generation of injection-molded reinforced thermoplastic
composites is not yet available, likely due to the complex interplay
between LCP and matrix components. In this study, we report on the
processing of poly(l-lactide) with two different LCPs, at
relatively low processing temperatures. The study focuses on critical
parameters for the morphological development and mechanical performance
of LCP-reinforced composites. The influence of blend composition and
the processing conditions, on the mechanical response of the composites,
is investigated using rheology, wide-angle X-ray diffraction, mechanical
analysis, and microscopy techniques. The study conclusively demonstrates
that both the matrix viscosity and viscosity ratio between the dispersed
and matrix phase, determine the deformation and breakup of the dispersed
LCP droplets during extrusion. In addition, the thermal dependence
of the viscosity ratio appears to be a critical parameter for the
composite performance after injection molding. For example, during
injection molding, stretching and molecular orientation of the LCP
phase into highly oriented fibrils are prevented when the viscosity
ratio increases rapidly upon cooling. In contrast, melt drawing proves
to be a more effective processing route as the extensional flow field
stabilizes elongated droplets, independent of the viscosity ratio.
Overall, these findings provide valuable insights in the morphological
development of LCP-reinforced blends, highlighting the importance
of the development of viscoelastic properties as a function of temperature,
and provide guidelines for the design of new LCP polymers and their
thermoplastic composites.