| Abstract Scope |
State-of-the-art processing of continuous-fiber-reinforced polymer composites typically involves resin impregnation followed by autoclave curing, relying on high temperatures and high pressures for hours (or sometimes days). This results in cost and production capacity challenges and constitutes the main bottleneck for the expansion of fiber-based composites to large-volume applications, such as structural automotive components, and complex part geometries. Additionally, most traditional composite manufacturing methods and state-of-the-art resins are ill-suited for infiltration of dense networks of nanoscale reinforcement, due to precursors’ high viscosity and small pore diameter. There is a need for rapid, energy-efficient manufacturing of composites, with a reduction in processing times from hours to minutes. Here we introduce in situ interfacial polymerization (ISIP), a low-temperature scalable manufacturing alternative to autoclave processing of structural nanocomposites. ISIP results in nanocomposites with tailored morphology and properties in a matter of minutes, through the interplay of fluid displacement, transport-reaction kinetics, and polymer precipitation. We discuss the large varieties of polymers (e.g., flame-retardant polyamide, thermoplastic polyetherimides and polyesters), composite morphologies, and final properties that can be obtained by ISIP. We also discuss fundamental understanding of the balance between capillary flow and reaction-precipitation kinetics in ISIP and its implementation in a first principle macrokinetics model to unlock ISIP-based composite manufacturing from a broad range of porous materials and nanofillers. |