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Concept
Pre-preg
Summary
Pre-preg is a composite material made from "pre-impregnated" fibers and a partially cured polymer matrix, such as epoxy or phenolic resin, or even thermoplastic mixed with liquid rubbers or resins. The fibers often take the form of a weave and the matrix is used to bond them together and to other components during manufacture. The thermoset matrix is only partially cured to allow easy handling; this B-Stage material requires cold storage to prevent complete curing. B-Stage pre-preg is always stored in cooled areas since heat accelerates complete polymerization. Hence, composite structures built of pre-pregs will mostly require an oven or autoclave to cure. The main idea behind a pre-preg material is the use of anisotropic mechanical properties along the fibers, while the polymer matrix provides filling properties, keeping the fibers in a single system.
Pre-preg allows one to impregnate the fibers on a flat workable surface, or rather in an industrial process, and then later form the impregnated fibers to a shape which could prove to be problematic for the hot injection process. Pre-preg also allows one to impregnate a bulk amount of fiber and then store it in a cooled area (below 20 °C) for an extended period of time to cure later. The process can also be time consuming in comparison to the hot injection process and the added value for pre-preg preparation is at the stage of the material supplier.
This technique can be utilized in the aviation industry. As in principle, prepreg has the potential to be processed batch sizes. Despite fiber glass having high applicability in aircraft specifically small aircraft motors, carbon fiber is employed in this type of industry at a higher rate, and the demand for it is increasing. For example, the characterization of Airbus A380 is handled by means of a mass fraction. This mass fraction is about 20%, and the Airbus A350XWB by a mass fraction of about 50% of carbon fiber prepregs. Carbon fiber prepregs have been used in the airfoils of the Airbus fleet for more than 20 years.
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