Gradual Impregnation during the Production of Thermoplastic Composites

Pre-impregnated intermediate materials based on thermoplastic polymer matrices are increasingly used for manufacturing CFRP structures. However, impregnation of the fiber with the polymer is a time-consuming process due to the high melt viscosity of thermoplastics. This leads to high manufacturing cost. This thesis develops and characterizes partially impregnated tapes. Process-induced effects on the properties of the polymer and composite are investigated as the tapes are impregnated during the subsequent heating and consolidation processes required to produce a component. By modifying the matrix with additives, effects on the viscosity due to degradation can be prevented and the operational throughput can be enhanced.