Contact resistance heating of unidirectional carbon fibre tows in a powder-epoxy towpregging line

Çelik, Murat; Noble, Thomas A.; Haseeb, Abdul; Maguire, James; Robert, Colin; Brádaigh, Conchúr M. Ó

doi:10.1080/14658011.2022.2108982

Cited by 10 publications

(11 citation statements)

References 31 publications

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“…The processing of similar composites using Joule heating can be scaled for large-scale fabrication in a roll-to-roll fashion, potentially with electrical leads on the rolls. Similar concepts have been demonstrated for epoxy-carbon fiber towpregs . Other alternatives would be to use flat electrical contacts that use pressure, as opposed to soldering, or noncontact electromagnetic heating, such as radio-frequency heating.…”

Section: Resultsmentioning

confidence: 99%

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Processing of Composite Electrodes of Carbon Nanotube Fabrics and Inorganic Matrices via Rapid Joule Heating

Upama

Mikhalchan

Arévalo

et al. 2023

ACS Appl. Mater. Interfaces

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Composites of nanocarbon network structures are interesting materials, combining mechanical properties and electrical conductivity superior to those of granular systems. Hence, they are envisaged to have applications as electrodes for energy storage and transfer. Here, we show a new processing route using Joule heating for a nanostructured network composite of carbon nanotube (CNT) fabrics and an inorganic phase (namely, MoS 2 ), and then study the resulting structure and properties. To this end, first, a unidirectional fabric of conductive CNT bundles is electrochemically coated with MoS 2 . Afterward, the conformally coated inorganic phase is crystallized via heat generated by direct current passing through the CNT ensemble. The Joule heating process is rapid (maximum heating rate up to 31.7 °C/s), enables accurate temperature control, and takes only a few minutes. The resulting composite material combines a high electrical conductivity of up to 1.72 (±0.25) × 10 5 S/m, tensile modulus as high as 8.82 ± 5.5 GPa/SG, and an axial tensile strength up to 200 ± 58 MPa/SG. Both electrical and mechanical properties are orders of magnitude above those of wet-processed nanocomposites of similar composition. The extraordinary longitudinal properties stem from the network of interconnected and highly aligned CNT bundles. Conductivity and modulus follow approximately a rule of mixtures, similar to a continuous fiber composite, whereas strength scales almost quadratically with the mass fraction of the inorganic phase due to the inorganic constraining realignment of CNTs upon stretching. This processing route is applicable to a wide range of nanocarbon-based composites with inorganic phases, leading to composites with specific strength above steel and electrical conductivity beyond the threshold for electronic limitations in battery electrodes.

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Section: Resultsmentioning

confidence: 99%

“…Similar concepts have been demonstrated for epoxy-carbon fiber towpregs. 33 Other alternatives would be to use flat electrical contacts that use pressure, as opposed to soldering, or noncontact electromagnetic heating, such as radio-frequency heating.…”

Section: Resultsmentioning

confidence: 99%

Processing of Composite Electrodes of Carbon Nanotube Fabrics and Inorganic Matrices via Rapid Joule Heating

Upama

Mikhalchan

Arévalo

et al. 2023

ACS Appl. Mater. Interfaces

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“…They investigated options to overcome these challenges, such as melting, during forming or application of a water-based gel, however, they were either impracticable, economically inefficient, or resulted in insufficient part quality. 17 Recent research is re-addressing the development and processing of carbon fiber (CF) yarns impregnated with SR. [19][20][21] Maguire et al 5,6,22,23 investigated an alternative approach, where the SR is molten to one or both sides of a textile layer (woven or non-crimp fabrics). For this a SR with relatively low melt viscosity (about 1 PaÁs was used).…”

Section: State-of-the-artmentioning

confidence: 99%

“…They investigated options to overcome these challenges, such as melting, during forming or application of a water‐based gel, however, they were either impracticable, economically inefficient, or resulted in insufficient part quality 17 . Recent research is re‐addressing the development and processing of carbon fiber (CF) yarns impregnated with SR 19–21 …”

Section: Introductionmentioning

confidence: 99%

Solid epoxy prepregs with patterned resin distribution: Influence of pattern and process parameters on part quality in vacuum‐bag‐only processing

Janzen,

May

2023

Polymer Composites

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Solid resins (SR) are fully reactive resin systems that are solid at room temperature. Up to a critical temperature they can be quasi‐infinitely molten and solidified without any relevant curing reaction. This study deals with novel SR‐based prepregs where a dry textile is covered with a regular SR (uncured) pattern, allowing for storage and draping at room temperature. The manufacturing of SR prepregs with accurate pattern geometries and the processing of the same into laminates with a pore volume content <1% using a vacuum bag only process is demonstrated for four pattern types and two curing cycles. The study furthermore shows that the pattern design has an influence on the mandatory drying phases as well as on fiber undulations. With sufficiently long drying phases, equivalent pore volume contents and interlaminar shear strength could be obtained with different pattern types.Highlights Manufacturing of carbon fiber (CF) solid epoxy prepregs with patterned resin distribution Epoxy powder processing Out‐of‐Autoclave manufacturing with vacuum‐bag‐only prepregs Interlaminar shear strength of carbon fiber reinforced plastics (CFRP) made of woven CFs Analysis of pore volume content and fiber undulation

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“…In the context of advanced composite materials, powder-based systems occupy several niches within the market: powder binder for preforming [5][6][7][8][9], powder towpregging [10][11][12][13][14], and powder semi-pregging [15][16][17][18][19]; each of which is shown in Figure 1. In the context of advanced composite materials, powder-based systems occup eral niches within the market: powder binder for preforming [5][6][7][8][9], powder towpre [10][11][12][13][14], and powder semi-pregging [15][16][17][18][19]; each of which is shown in Figure 1. In the case of powder binders, typically, only 3-9 wt% of polymer powder is a to dry reinforcing fabric.…”

Section: Introductionmentioning

confidence: 99%

Hygroscopicity in Epoxy Powder Composites

Maguire,

Wang,

Ó Brádaigh

2024

Powders

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Epoxy powders offer a low-cost way of manufacturing thick-section composite parts, such as those found in wind and tidal turbines. Currently, their processing cycle includes a lengthy drying stage (≥15 h) to remove ambient moisture. This drying stage prevents void defect formation and, thereby, a reduction in mechanical properties; however, it constitutes up to 60% of the processing time. Little research has been published which studies the drying stage or its optimisation. In the present work, experimental and simulated analyses are used to investigate the effects of hygroscopicity in epoxy powder composites. Tests are performed to quantify the void content of dried and undried laminates and to measure its impact on transverse flexural strength. Dynamic vapour sorption analysis is used to study the sorption behaviour of the epoxy powder. It is shown that the epoxy powder is slightly hygroscopic (1.36 wt%) and exhibits sorption behaviour that is characteristic of glassy polymers. This results in up to 4.8% voids (by volume) if processed in an undried state, leading to a 43% reduction in transverse flexural strength. A modified linear driving force model is fitted to the desorption data and then implemented in existing process-simulation tools. The drying of a thick epoxy powder composite section is simulated to investigate the influence of powder sintering on the duration of the drying stage. Process simulations reveal that a standard drying cycle prematurely sinters the powder, which inhibits moisture release. By maintaining the powder state, simulations show that the drying cycle can be reduced to 5 h.

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Contact resistance heating of unidirectional carbon fibre tows in a powder-epoxy towpregging line

Cited by 10 publications

References 31 publications

Processing of Composite Electrodes of Carbon Nanotube Fabrics and Inorganic Matrices via Rapid Joule Heating

Processing of Composite Electrodes of Carbon Nanotube Fabrics and Inorganic Matrices via Rapid Joule Heating

Solid epoxy prepregs with patterned resin distribution: Influence of pattern and process parameters on part quality in vacuum‐bag‐only processing

Hygroscopicity in Epoxy Powder Composites

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