Hybrid multi-scale thermoplastic composites reinforced with interleaved nanofiber mats using in-situ polymerization of cyclic butylene terephthalate

Mechanically flexible electrospun carbon and glass nanofiber mats (Le., ECNF-mats and EGNF-mats) were prepared by electrospinning followed by thermal treatments; subsequently, a technique was applied to fabricate two types of mull-scale thermoplastic composites, involving infiltration of molten cyclic butylene terephthalate (CBT) followed by in-situ polymerization under compression. For the first composite type, eight conventional carbon fabrics were interleaved with seven ECNF-mats. For the second composite type, eight conventional glass fabrics were interleaved with seven EGNF-mats. Compared to the values acquired from the corresponding control samples without nanofiber mats, the interlaminar shear strength, flexural strength, flexural modulus, and work of fracture acquired from the hybrid mull-scale composite containing ECNF-mats were increased by 32%, 25%, 19%, and 33%, respectively; while the values acquired from the hybrid multi-scale composite containing EGNF-mats were increased by 66%, 43%, 17%, and 64%, respectively. Furthermore, the enhancements of out-ofplane properties were not at the expense of in-plane tensile strength or modulus. The study indicated that the employed fabrication technique could be adopted as an efficient approach to produce polybutylene terephthalate (PBT) thermoplastic composites through in-situ polymerization of CBT oligomer; and the ECNF-mats and EGNF-mats could be utilized as innovative reinforcement fillers for enhancing the performance of structural thermoplastic composites.