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Fiber reinforced composites are increasingly used in high value applications. A novel technology (NanoWeld®) enhancing the structural integrity of the interlayer has demonstrated promising results; however, manufacturing issues related to scalability need to be overcome. The developed technology relies on consolidating thermoplastic nanofiber nonwoven veils onto technical dry fabrics through roll-to-roll ultrasonic welding. The enhanced technical dry fabrics can be further processed as any other technical fabrics for the composites industry. An alternative solution for consolidation is proposed here, based on a thermo-compressive approach to address the scalability issue. A finite element model has been employed to simulate the operating conditions and provide information for optimization of the process. Its results demonstrate that consolidation is achieved rapidly, indicating that the production rate could be accelerated. The quality of enhanced technical dry fabrics produced using the proposed consolidation assembly has been evaluated using scanning electron microscopy as well as mechanical testing of fiber reinforced composites. The mechanical response of such manufactured composites has been compared against benchmark NanoWeld® composites, demonstrating superior performance.

Evaluation of a Thermal Consolidation Process for the Production of Enhanced Technical Fabrics