Dry Electrostatic Spray Coated Towpregs for Thermoplastic Composites

Abstract

Though the processing steps for the manufacture of thermoplastic composites present little difficulty when compared to those for thermoset composites, it is not cost effective as a result of difficulty in accomplishing thorough infusion of resin into fibers and fibrous structures. Tremendously high viscosity for thermoplastic resin leads to numerous problems in the manufacturing process of thermoplastic composites. Pre-impregnation processes such as melt impregnation or solution impregnation, tend to form a stiff towpreg that cannot be used for any textile preforming operation. Powder coating can be a destined to be a cost effective as well as efficient processing technology to produce a flexible towpreg. A method for production of flexible towpregs for thorough infusion of resin into fibers using electrostatic spray gun, which involves powder coating a bundle of filaments is described. During the powder coating process using electrostatic spray gun, powder particles fetched by a conveying air stream, from a fluidizing hopper, are charged in the high voltage corona discharge by ion bombardment and transported to the fiber tow through the combination of electrostatic, aerodynamic and gravitational forces. Aerodynamic forces have the obligation to carry the powder particles to the tow where electrostatic forces dominate and cause the adherence of powder particles to the potentially grounded tow. After the powder deposition, tow is made to pass through convective oven where powder particles glue to the reinforcement as a result of partial liquefaction of the powder. The towpreg formed is then wound by the take up device. Take up device is equipped with dancer arm which ensures constant line tension and thereby consistent powder deposition. The effects of process variables of the electrostatic spray process such as corona voltage, fluidizing air pressure, conveying air pressure, distance of gun from tow and tow velocity on maximum powder deposition are investigated and reported.