Carbon fiber (CF) reinforced thermoplastic polyethylene terephthalate (PET) laminate composites with light weight, high strength, excellent damage tolerance, and recyclability have garnered increasing attention. However, the weak interface between inert CF and PET resin, as well as the difficulty of impregnating the considerably high melt viscosity of PET matrix into the CF bundles, have impeded further development of the CF/PET composites. To settle the challenge, the chopped ultra-thin CF tapes (thickness of 40 μm and length of 30 mm) reinforced PET composite laminates were prepared by mechanical spreading technology, following with random stacking and molding technology via the plasma treatment and PET/carbon nanotubes (CNT) sizing. As the results, the optimal interlaminar shear strength (ILSS), tensile strength, and Young's modulus of the chopped ultra-thin CF tapes reinforced PET composites (with 1.0 wt% CNT) achieved 42.4 MPa, 780.9 MPa, and 47.8 GPa, which increased by 41.9 %, 40.7 %, and 68.9 %, respectively, compared to unmodified CF/PET composites. Especially, the porosity of the composites reached 0.68 %, decreased by 84.3 %. Therefore, combining the easy infiltrability of chopped ultra-thin CF tapes technology and the multiscale interfacial reinforced strategy (plasma treatment and PET/CNT sizing) is an effective way to reduce the porosity and enhance the mechanical properties of the thermoplastic composites.
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