PPESK-Modified Multi-Functional Epoxy Resin and Its Application to the Pultrusion of Carbon Fiber

Multi-functional epoxy resins are generally brittle due to their high crosslinking densities, which can limit their use for applications that require impact resistance. Pultruded poly(phthalazinone ether sulfone ketone) (PPESK)-modified epoxy resins were prepared and their curing behaviors, heat resistance properties, and viscosity changes investigated. The glass transition temperature of these resins was found to increase with increasing PPESK content; however, these values were still compatible with the pultrusion process. Little change in the tensile strength and elongation lengths at breaking point were observed for blended PPESK/multi-functional epoxy resin containing 4–6% PPESK, and its viscosity levels were still within the requirements of the pultrusion process. Carbon fiber/multi-functional epoxy resin/PPESK (CF/E/PPESK) composites were also prepared and their performance investigated. The bending radius of these PPSEK-modified composites could reach up to 55 D with no cracking or peeling observed in their surface layers. The fatigue frequency of the sinusoidal waveforms for the composite did not change after one million fatigue test cycles, meaning that a strength retention rate of >90% was achieved. Therefore, this study describes a powerful approach for preparing toughened multi-functional epoxy resins that are well suited to pultrusion processes.