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Epoxy Prepregs

Epoxy Prepregs

With advanced manufacturing equipment and strict quality control, we provide customers with high-quality products and after-sales services.
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Description
Why Choose Us
 

Professional Team
We have an excellent R&D and technical team that has been conducting diving research for many years and currently has more than 100 national patents.

 

Main market
North America, South America, Eastern Europe, Southeast Asia, Africa, Oceania, Mid East, Eastern Asia, Western Europe.

 

Quality Control
With advanced manufacturing equipment and strict quality control, we provide customers with high-quality products and after-sales services.

 

One stop solution
Provide comprehensive services, including initial consultation, production tracking, and after-sales service, to provide you with a one-stop solution.

 

What is Epoxy Prepregs

 

 

Epoxy prepregs are combination of epoxy resin, curing system and reinforcing fbers. Epoxy resin is the intermediate substrate for composite production, and the prepregs with its resin matrix has not only excellent adhesive properties, but also good toughness and flexibility. Also have excellent molding and curing characteristics in the non-fber direction.

 

 

Benefits of Epoxy Prepregs
 
Peerless Mechanical Performance

Its simple, an optimized fiber to resin ratio provides the best mechanical properties in the lightest weight for a composite design or fabrication. Prepregs provide just that.

Process Robustness

Epoxy Prepregs a much cleaner and easier processing from ply cut to demold. Clean and easy ply cut of prepregs result in accurately ply shapes that are then easily laid up into mold surfaces. No longer is there a sticky mess of resin coming from your gloves while trying to layup large plys of complex surfaces while handling brushes or squeegees. No longer is there even resin mixing, no working times down to the min to worry about, no complicated system of resin feed lines, no worrying if the spray adhesive will affect a part's surface finish. The list is nearly endless with it comes to reducing man hours, touch times, and efficiency of composite fabrication processes.

Unmatched Repeatability & Uniformity

Process robustness and consistency go together in effectively fabricating repeatable high-quality parts. Prepregs mitigate process variation as it is optimized with features such as tack, cured ply thickness, and a debulking capability that make even the most complicated laminates easier. Prepregs are consistent, simply pull the backing from the cut plys and lay it into the mold, conforming the ply to the mold as needed. Once the layup is complete, the bagging and curing process is much less complicated than that of an infusion process.

Co-cure > Secondary Cure

One large advantage to using prepregs in composites lies in the ability to co-cure many aspects of a composite laminate in one shot. Co-curing adds to the high-performance capability because co-cured laminates share stronger bonds than that of secondary bonds. Products such as film adhesives allow core bonded composites to be made in one cure run with the prepreg fabric layers. In addition, large core pieces can be joined via syntactic films, lighting strike protection can be added to the surface of conductive materials and other film adhesives can be used to provide a higher quality surface finish. In short, many of vacuum infusion and traditional layup shortcomings are made simple using prepreg products.

 

What are the Applications of Epoxy Prepregs
Honeycomb Panel for Racing Boat
Car Interior Panels
Aviation Honeycomb Floor Panels
Phenolic Prepregs

Aerospace field
The aerospace field has very strict requirements for materials, which require high strength, light weight, corrosion resistance, high temperature resistance and other properties. As a high-performance composite material, epoxy prepreg has been widely used in the aerospace field. In aircraft manufacturing, epoxy prepregs can be used to manufacture wings, fuselages, tails and other components. Because epoxy prepreg has excellent mechanical properties and corrosion resistance, it can meet the requirements of aircraft in high-speed flights and complex environments. In addition, epoxy prepreg also has good high temperature resistance and can maintain stable performance in high temperature environments.

Automotive field
The automotive field is another important area for epoxy prepreg applications. In automobile manufacturing, epoxy prepreg can be used to manufacture body, frame, engine and other components. Because epoxy prepreg has excellent mechanical properties and corrosion resistance, it can meet the requirements of automobiles operating at high speeds and in complex environments. In addition, epoxy prepreg also has good wear resistance and impact resistance, which can improve the driving safety and service life of cars. At the same time, epoxy prepreg also has good insulation properties and can meet the insulation requirements of automotive electronic components.

Electronic field
The electronic field is another important area for epoxy prepreg applications. In electronics manufacturing, epoxy prepregs can be used to manufacture circuit boards, electronic components and other components. Because epoxy prepreg has good electrical insulation properties, stability and weather resistance, it can meet the requirements of electronic equipment in complex environments. In addition, epoxy prepreg also has good corrosion resistance and wear resistance, which can improve the reliability and service life of electronic equipment. At the same time, epoxy prepreg also has good processability and can meet the processing requirements in the manufacturing process of electronic equipment.

Sports equipment field
The sports equipment field is another important area for epoxy prepreg applications. In sports equipment manufacturing, epoxy prepregs can be used to make components such as golf clubs, skis, and bicycle frames. Because epoxy prepreg has excellent mechanical properties and corrosion resistance, it can meet the requirements of sports equipment in complex environments.

 

Aviation Interior Honeycomb Panels

 

Components of Epoxy Prepregs

Fiberglass
The fiberglass serves as the structural framework that provides mechanical support. It is typically woven fiberglass cloth, although non-woven fiberglass mat is also sometimes used. The weave style (e.g., plain weave, satin weave) and weight (ounces per square yard) can be varied to achieve different mechanical properties. Heavier weights and tighter weaves provide more strength and rigidity. Lighter weights allow more resin impregnation for better layer-to-layer adhesion.

Thermoset Resin
The resin coats and impregnates the fibers, acting as the adhesive glue that holds the PCB layers together. The most common resins used are epoxy, polyimide, or bismaleimide (BMI). Epoxy is the most popular due to its suitable dielectric properties, dimensional stability, and ease of processing. The resin may also contain fillers like silica to modify thermal and electrical characteristics.

 

 

Epoxy Prepregs Properties

Resin Content
The percentage of resin relative to fiberglass by weight, typically around 50%. More resin improves adhesion but reduces thermal conductivity.

Flow
How much the resin flows under heat and pressure. Higher flow fills spaces but risks excess squeeze-out. Low flow reduces movement but may leave voids.

Drape
Qualitative measure of limpness and conformability. Improves ply conformance over uneven surfaces.

Tack
Stickiness of resin. Balances ease of handling against moving during layer alignment.

Gel time
Time to cure at a given temperature. Longer gel times aid multilayer alignment.

Shelflife
How long the prepreg can last before the resin advances too far. Typically 1-2 years at room temperature.

DSC
Differential scanning calorimetry traces measure the cure exotherm. Used to set lamination cycles.

Tg
Glass transition temperature after cure. Indicates heat resistance.

CNC Milled Part

 

Process of Epoxy Prepregs
 

Hot Melt Process
The process involves the application of heat and pressure. It is used in the production of both fabric and unidirectional prepregs. The process can be defined by two distinct stages. The heated resin is first coated with a thin film on a paper substrate. In the prepreg machine, the resin is then left to interact with the reinforcement material. Lastly, using pressure and heat, the resin is reinforced or impregnated into the fiber to give the final result.

 

Solvent Dip Process
This process involves the use of a solvent bath. It is only effective in the production of fabric prepregs like woven fabrics and high-temperature resins. Here, the resin is dissolved in a solvent bath then the reinforcing fabric is dipped in the solution. The solvent is then dried using a drying oven.The major disadvantage of this method is the fact that there are solvent remnants on the prepreg and could result in adverse evolution problems.

 

Resin Film Process
This is the modern method of prepreg preparation and is highly preferred by many manufacturers. In this process, the resin film is controlled to the desired thickness then goes through the prepreg process.With the resin film process, it is easy to achieve consistency and specified fiber aerial weight since the procedure allows for better control of the resin thickness.

 

 

Interior Honeycomb Panel for High-speed Railroad

 

Applications of Epoxy Prepregs vs. Core

Complex PCBs
Prepreg vs. Core materials are essential in the formation of complex PCBs. Engineers may get a more complex epoxy Prepregs when there is a complex PCB. They can simply utilize several varieties of Prepreg to reach the required thickness for the board and Prepreg.

Multilayer PCBs
As we had stated earlier, Epoxy prepregs is important in the formation of multilayer PCBs. It actually holds the different layers of the multilayer PCB together. When stacking the board's layers together, fusing will be necessary. How to do this? It's simple – just expose them to high temperatures. There will be a similarity between the Prepreg thickness and that of the board.

 

 

Recent Advancements in Epoxy Prepregs Composites

Automated Manufacturing
Advancements in automated manufacturing techniques, such as automated tape laying and fiber placement, have significantly reduced labor costs and improved product consistency.

Nanotechnology Integration
The incorporation of nanomaterials, such as carbon nanotubes and graphene, into prepreg composites has resulted in materials with even greater strength and conductivity.

Recycling
Efforts are being made to develop recyclable prepreg composites, addressing environmental concerns and reducing waste.

3D Printing
3D printing technologies are being adapted to produce complex prepreg composite structures with precision, expanding their applications further.

Over Expanded Honeycomb Core

 

Things to Note During The Epoxy Prepreg Layup Process
 
 
Steel bar cleaning

Before prepreg lay-up, the steel bars first need to be cleaned. Because grease, rust, etc. on the surface of the steel bars will affect the adhesion effect and quality of the prepreg. Therefore, it needs to be cleaned with a brush or compressed air to make the surface of the steel bar dry and smooth.

 
Preparation work before laying

Before laying the layers, preparation work is required. Including measuring, cutting and rebar placement. First, the components need to be measured to determine their dimensions so that the layup calculation can be carried out. The epoxy prepreg strips are then cut to the required length and packed in bulk or rolled. Finally, the steel bars are positioned and measured with measuring tools, and the steel bars are firmly fixed.

 
Epoxy prepreg quality

Epoxy prepreg is a coating on the surface of precast concrete components that can effectively protect the concrete surface and reduce its exposure to external influences. Therefore, when laying up epoxy prepreg, you need to pay attention to the quality of the prepreg. Prepregs that comply with national standards should be selected, and the quality of the prepregs needs to be tested to ensure that their quality meets the design requirements.

 
Construction Technology

In the process of epoxy prepreg laying, construction technology is also very important. Generally speaking, the appropriate construction method should be selected based on the properties and characteristics of epoxy prepreg. During construction, the epoxy prepreg should be evenly coated on the reinforced concrete surface, and a throttle valve should be used to control the coating amount to avoid waste. At the same time, attention should be paid to environmental factors such as construction temperature and humidity to ensure the quality and adhesion effect of epoxy prepreg.

 

 

 

Our Factory

Jiaxing CMAG Composite Material Co., Ltd. (Abbreviated as "CMAG" or "the Company") was established in 2013 with a registered capital of 83,088,000RMB. The company covers an area of about 67 acres with a standardized factory building of about 40,000 m in the National High-tech Industrial Development Zone, Xiuzhou District, Jiaxing City, Zhejiang Province, China.The company is mainly engaged in the research, development and mass production of core materials, honeycomb sandwich panels (including the production of prepreg from various materials), full-composite structural components and other kinds of high-performance composite materials. The company's products have been widely used in aviation, rail transportation, racing boat, sporting goods and other industries.

 

Our Certificates
 
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FAQ
 

Q: What is the typical glass transition temperature of standard FR-4 prepreg?

A: Standard FR-4 prepreg formulations typically have glass transition temperatures in the range of 130°C to 140°C once fully cured. Some "high Tg" versions may reach 170°C Tg.

Q: What weave styles and weights of fiberglass fabric are commonly used in prepregs?

A: The most common weaves used are 106 and 1080 style woven fiberglass, ranging from lightweight 7628 to heavier 2116 or 3313 styles. Weights between 1-5 ounces per square yard are typical for most applications.

Q: How does resin content affect prepreg properties and performance?

A: Higher resin content increases layer-to-layer adhesion but reduces thermal conductivity through the dielectric. It also increases cost. Typical resin content is around 50%, with 45-55% being common.

Q: What is the difference between thermoset and thermoplastic prepregs?

A: Thermoset prepregs use resins that permanently cure when heated, while thermoplastic resins soften on reheating allowing some reworkability. Thermoplastic prepregs have limited use currently due to processing challenges.

Q: How does prepreg storage life compare for freezer versus room temperature conditions?

A: Properly frozen prepreg at -18°C can last 6-12 months before the resin advance affects properties. Room temperature storage typically allows 1-3 months depending on the formulation.

Q: Why use prepreg for tooling?

A: Prepreg is the most reliable way to control the variables that are involved in composites production, including the resin content, which is typically around 40% for structural composites. Prepreg also enables control of the thickness of the laminate with an even distribution of resin throughout the prepreg.

Q: What should you consider when choosing material for composite tools?

A: It is critical that the tool has excellent dimensional stability. This is important at room temperature as well as in the curing cycle. As you apply heat, parts will expand, which is known as coefficient of thermal expansion (CTE). Composite materials, like prepregs, are good tooling materials because the CTE match between the tools and parts enables more precise composite parts.As you cure parts in oven or autoclave, it is important to keep a uniform consistent temperature throughout the part and the tool itself. Product data sheets will typically include a ramp rate, or how fast you can heat the product to keep an even temperature throughout as it is curing. You should also consider the part thickness, which affects heat capacity. Thicker products will require more heat to reach the required temperature.

Q: What is the difference between prepreg and epoxy?

A: "Prepreg" is the common term for a reinforcing fabric which has been pre-impregnated with a resin system. This resin system (typically epoxy) already includes the proper curing agent. As a result, the prepreg is ready to lay into the mold without the addition of any more resin.

Q: What resin is used in prepreg?

A: The majority of aramid fiber prepregs use epoxy resins which require high-temperature/pressure cycles to flow, consolidate, and cure. This is usually done in an autoclave process. However, prepregs with other classes of resins, e.g., bismaleimides and polyesters, are made for special purposes.

Q: What is epoxy used for carbon fiber?

A: Some of the available epoxy for carbon fiber options today include: Cyanoacrylate: Known to many manufacturers as "instant adhesive," this is excellent for bonding carbon fiber reinforced polymers. Single component epoxies: High-level single component epoxies are specifically designed to work with carbon fiber.

Q: What is a prepreg used for?

A: Prepregs are typically used by experienced fabricators who are interested in minimizing the weight of their part. Typical applications include aerospace, racing, sporting goods, pressure vessels, and commercial products. Generally, prepregs are used by fabricators who have experience with hand layup and vacuum bagging.

Q: What are the characteristics of prepreg?

A: Basic prepreg selection is based on characteristics such as fiber, tow size, and weave selection, all of which are similar features to that of traditional fabrics. Prepregs will often come with a defined "cured ply thickness" and density in addition to providing the precise fiber to resin ratio.

Q: How is prepreg made?

A: In the hot melt prepreg method, the resin film is cast on a fibre-based carrier material, before both materials are passed between heated rollers. This transfers the resin to the carrier material and forces the resin to impregnate the carrier's fibres.

Q: What is the difference between dry fiber and prepreg?

A: Dry carbon fiber's name also comes from its manufacturing process. During manufacture, dry carbon fiber has its resin pre-impregnated, that is, literally built into the fiber. Since no resin is being directly applied, the fiber is "dry". Pre-impregnated fiber is called "pre-preg" in the carbon fiber industry.

Q: What are the pros and cons of prepreg?

A: Prepregs have the desired resin content built in. Better looking parts: With the elimination of air bubbles, prepregs allow smooth glossy surfaces more easily than with hand laminated parts. Disadvantages: Usable Shelf Life: As a prepreg is a catalyzed material, shipping and storage in refrigeration are required.

Q: How is prepreg carbon Fibre made?

A: Tech Explained: Carbon Fibre Prepreg - Racecar Engineering
To manufacture UD prepregs, multiple bobbins of fibre are aligned on a creel, each supplying one tow of carbon fibre with filaments that are spread out and lined up. The resin film is then applied to the fibre through the manufacturing process.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.Conventional thermoplastic prepreg generally features a fully polymerized matrix with high melt viscosity, and processing requires high pressure and temperature to ensure proper fiber bed impregnation and void removal.

Q: What is the difference between prepreg and core?

A: Both the core and the prepreg are essential components of the PCB. While the core is a base PCB material, a multilayer PCB is held together by the prepreg. The difference between the two lies in the fact that the core is cured, while prepreg materials are malleable which means it can be easily formed into sheets.

Q: What is the difference between wet and prepreg?

A: Laminate properties in Prepreg Carbon fiber can be 10%- 20% better than wet lay-up at a lower weight (because less resin is used to do the same job). This Prepreg and Autoclave process is used to manufacture the exceedingly strong, but light, chassis centers (often known as 'tubs') for Formula 1 race cars.

Q: What is the prepreg method for composites?

A: What is a Prepreg? Prepregs are composite materials in which a reinforcement fiber is pre-impregnated with a thermoplastic or thermoset resin matrix in a certain ratio. Prepregs have unique properties as they are cured under high temperatures and pressures.Composites do require less maintenance than traditional materials, but they are more expensive to fix when they need repair. One disadvantage of using composites is that they are not biodegradable. However, they do have some positive impact on the environment because of their longevity and fuel-savings.

Q: Why use prepreg carbon fiber?

A: Uncured prepreg carbon fibre is easy to handle and can be cut and laid precisely into detailed and intricate moulds making the process ideal for smaller, complex parts that might be very difficult using alternative processes such as traditional laminating, vacuum bagging or resin infusion.The prepreg and core are two different parts of the PCB. For starters, the core is an FR4 material with copper traces. Whereas, the prepreg is fiberglass impregnated with resin. It is the prepreg that holds the core together on the PCB.

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