A theoretical study of resin flows for thermosetting materials during prepreg processing

A flow model which describes the process of resin consolidation during prepreg lamination was developed. The salient features of model predictions were explored. It is assumed that resin flows in all directions originate from squeezing action between two approaching adjacent fiber/fabric layers. In the horizontal direction, a squeezing flow between two nonporous parallel plates is analyzed, while in the vertical direction a poiseuille type pressure flow through porous media is assumed. Proper force and mass balance was established for the whole system which is composed of these two types of flow. A flow parameter, CF, shows to be a measure of processibility for the curing resin. For a given external load-F the responses of resin flow during prepreg lamination, as measured by CF, are categorized into three regions: (1) the low CF region where resin flows are inhibited by the high chemoviscosity during initial curing stages; (2) the median CF region where resin flows are properly controllable; and (3) the high CF region where resin flows are ceased due to fiber/fabric compression effects. Resin losses in both directions are calculated. Potential uses of this model and quality control of incoming prepreg material are discussed.