Resin Infusible Carbon Uni Broadgood Stabilized by Un-Catalyzed Epoxy Resin Binder

Numerous carbon fiber uni products are widely used in the composites industry. These various products vary in cost, processing method, and final composite properties obtained. For example, previous studies suggest that crimp and/or thermoplastic stitch sites in traditional woven uni and stitch-bonded fabrics, respectively, lead to limited fatigue properties relative to composites derived from autoclaved prepreg tapes. However autoclave processing can be expensive relative to methods such as RTM. TEAM, Inc. proposes to solve the fatigue resistant resin infusible uni broadgoods problem by developing a novel carbon uni construction in which traditional hot melt filling fiber sites are substituted with sites of un-catalyzed epoxy binder. The epoxy binder, a solid at room temperature, will serve to stabilize the fabric for handling but can be melted during resin infusion such that it will mix and cross-link with the incoming catalyzed resin flow, leaving a totally unidirectional laminate. Fatigue properties of the resulting composite are expected to be superior to traditional uni woven and stitched fabrics since the developed product will have no crimp and no thermoplastic constituents. The proposed solution will be compatible with existing uni fabric weaving equipment, limiting risk and reducing manufacturing CapEx requirements for initial commercialization.