A new NASA LaRC Multi-Purpose Prepregging Unit

A multi-purpose prepregging machine has been designed and built for NASA Langley Research Center. The machine has numerous advantages over existing units due to its various modular components. Each of these can be used individually or simultaneously depending on the required prepregging method. A reverse roll coater provides the ability to prepare thin films from typical hot-melt thermoset formulations. Also, if necessary, the design allows direct fiber impregnation within the reverse roll coater gap. Included in the impregnation module is a solution dip tank allowing the fabrication of thermoplastic prepregs from solution. The proceeding modules within the unit consist of four nip stations, two hot-plates, a hot-sled option and a high temperature oven. This paper describes the advantages of such a modular construction and discusses the various processing combinations available to the prepregger. A variety of high performance prepreg material systems were produced on IM7 (Hercules) carbon fiber. These included LaRC RP46, a PMR-type resin processed from methanol and two polyamide acids, LaRC IA and LaRC ITPI, prpregged from N-methyl pyrrolidinone (NMP). Parameters involved in the production of these prepreg materials are presented as are the mechanical properties of the resulting good quality laminates. A brief introduction into the existing prepregging science is presented. Topics relating to solution prepregging are identified with a focus on the current research effort and its future development.