Technology for lateral spreading of fibre bundles for applications in manufacturing thermoplastic composites

• Published in: Composites. Part A, Applied science and manufacturing Applied science and manufacturing, 2023-04, Vol.167, p.107422, Article 107422
• Main Authors: Moradi, Alireza, Sun, Changze, Guan, Zhongwei, Rastegarzadeh, Sina
• Format: Article
• Language: English
• Subjects: Fibre spreading; Fibre tow infiltration; Powder processing; Thermoplastic resin
• ISSN: 1359-835X; 1878-5840
• DOI: 10.1016/j.compositesa.2022.107422

•This article introduces a novel fibre spreading assembly.•The design is based on lateral opening of fibres mixed with polymer powder slurry.•The process includes infusion of polymer particles between fibre filaments.•The spreader can open the fibre bundle via a reciprocating motion of rollers.•The effects of fixed or rotating rollers on fibre spreading are discussed. In the current study, the effectiveness of a novel fibre spreading assembly for manufacturing of high-performance thermoplastic composites is evaluated. The spread of S2-glass fibre was measured after the fibre bundle was dipped in a resin bath containing polyetherether ketone (PEEK) powder slurry and subsequently passed through the spreading processes. The effects of motion frequency, amplitude and fixed or rotating rollers on the degree of fibre spreading were studied. A frequency of 5 Hz along with 6 mm of motion amplitude was found as one ideal combination in providing efficient and effective fibre spreading. Observations indicated that the width of the as received S2-glass fibre tow could be increased up to 7 times when rotating rollers were used, and up to 10 times when fixed rollers were utilised.