A novel method and equipment for manufacturing high‐performance fiber‐reinforced polymer composite based on chaotic mixing and stretching force field

Abstract Fiberglass‐reinforced composites are extensively utilized in a diverse range of fields. Nonetheless, relying on the high shear forces generated during twin screw extruder processing to enhance the dispersion and distribution of glass fibers (GFs) can result in GF breakage and the degradation of the molecular chains of polyamide (PA). Consequently, this leads to a diminished performance of the composite material. In this study, high‐performance PA6/GF composites were effectively fabricated through the utilization of a dual‐speed non‐twin screw extruder operating within a chaotic field. Furthermore, optimization was achieved by substituting the kneading block (KB) with a perturbation ring element (PRE). In this paper, a comparative analysis was conducted between the flow fields and experimental results obtained from varying thread arrangements. The result indicates that, in comparison to KB with discontinuous structures and sudden geometric shapes, PRE elements possessing open structure in both the transverse and longitudinal directions effectively mitigated the shear effect and residence time during processing. This led to the significant enhancement of the residual length of the GF, molecular weight of PA6, heat distortion resistance and thermal stability of the composites. Additionally, enhanced performance was observed in PA6/GF composites prepared using the PRE configuration. Specifically, PA6/GF composites prepared by PRE S3 configuration showed outstanding impact strength of 13.3 kJ/m² and a tensile strength of 151.6 MPa, representing respective increases of 15.7% and 6.9% compared with those prepared using the twin screw extruder (TSE). This work introduced an innovative device and molding technique for the production of high‐performance fiber‐reinforced polymer composites. Highlights High‐performance PA/GF was successfully manufactured by non‐twin screw extruder. The modified non‐twin screw leaded to better dispersion and distribution of GF. The damage of fiberglass and the degradation of PA were significantly reduced. The mechanical properties were significantly improved without using additives. The heat distortion resistance and thermal stability of PA/GF were improved.