Relationship between Process Conditions and Mechanical Properties of Unidirectional Prepregs Prepared by Melt Impregnation

This study focuses on the processing of prepregs and the mechanical properties of compositespreparedusing theprepregs,revealing certaincrucialprocessrequirements.Tothebest of our knowledge, studies correlating the prepreg manufacturing process and the mechanical properties of composites prepared using the prepregs have not been reported.Normally, carbon fiberreinforcedthermoplastic(CFRTP)ispreparedusing theresinfilminfusionprocess.However, we used themelt impregnation method to manufacture unidirectional polypropylene prepregs to achieveefficient impregnationofcarbonfiberbundles.Thismethodmerelyrequiresanextruderto infuse the melt resin, making it possible to control different degrees of acid modification of polypropyleneand theprocesstemperatureto investigatethecompositeproperties.Asaresult,we could optimize the process parameters and the temperature conditions to manufacture unidirectional carbon fiber prepregs and successfullyprepare good composite laminates with excellent carbon fiber distribution and lowvoid content (below1.0%).