Fabrication of continuous fiber-reinforced thermoplastic composites with structural gradient from sheath-core type bicomponent fibers

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Sheath-core type bicomponent fibers of polypropylene (PP) as a sheath component and thermotropic liquid crystalline polymer (TLCP) as a core component were prepared by the highspeed melt spinning process. Continuous fiber reinforced thermoplastic composites, in which TLCP acts as a reinforcing fiber and PP as a matrix polymer, were fabricated by the compression molding of these fibers. In the melt spinning, the attainable highest take-up velocity of TLCP was improved by co-processing with PP. Tensile modulus and strength of the TLCP component in the PP/TLCP bicomponent fibers increased with an increase in the take-up velocity. Comparison of wide-angle X-ray diffraction patterns of starting bicomponent fibers and fabricated composites indicated that the orientation relaxation of TLCP did not occur in the compression molding process. Accordingly, the tensile modulus and strength of the PP/TLCP composites were similar to those of the bicomponent fibers. Continuous fiber reinforced thermoplastic composites with various types of fiber content distributions were fabricated from the bicomponent fibers in which sheath-core composition was changed gradually in the spinning process. In the three-point bending test, the composites with two different types of symmetric structural gradients, one with higher TLCP fiber content near the surfaces than in the center and the other with higher TLCP content in the center than near the surfaces, exhibited different flexural moduli even though the overall TLCP contents were comparable. In the three-point bending test of a composite with asymmetric structural gradient, the yielding behavior and maximum flexural load varied depending on the direction of load application although the initial flexural moduli were similar.