Resin Infusible Carbon Uni Broadgood Stabilized by Un-Catalyzed Epoxy Resin Binder Navy SBIR FY2015.1 Sol No.: Navy SBIR FY2015.1 Topic No.: N151-072 Topic Title: Resin Infusible Carbon Uni Broadgood Stabilized by Un-Catalyzed Epoxy Resin Binder Proposal No.: N151-072-0900 Firm: T. E. A. M., Inc. 841 Park East Drive P.O. Box 25 Woonsocket, Rhode Island 02895 Contact: Aaron Tomich Phone: (401) 762-1500 Web Site: www.teamtextiles.com Abstract: Numerous carbon fiber uni products are widely used in the composites industry. These various products vary in cost, processing method, and final composite properties obtained. For example, previous studies suggest that crimp and/or thermoplastic stitch sites in traditional woven uni and stitch-bonded fabrics, respectively, lead to limited fatigue properties relative to composites derived from autoclaved prepreg tapes. However autoclave processing can be expensive relative to methods such as RTM. TEAM, Inc. proposes to solve the fatigue resistant resin infusible uni broadgoods problem by developing a novel carbon uni construction in which traditional hot melt filling fiber sites are substituted with sites of un-catalyzed epoxy binder. The epoxy binder, a solid at room temperature, will serve to stabilize the fabric for handling but can be melted during resin infusion such that it will mix and cross-link with the incoming catalyzed resin flow, leaving a totally unidirectional laminate. Fatigue properties of the resulting composite are expected to be superior to traditional uni woven and stitched fabrics since the developed product will have no crimp and no thermoplastic constituents. The proposed solution will be compatible with existing uni fabric weaving equipment, limiting risk and reducing manufacturing CapEx requirements for initial commercialization. Benefits: The performance advantage of the proposed solution lies in improved fatigue properties resulting from elimination of crimp and thermoplastic binders. The manufacturing advantage is two-fold. First, the product can be infused out of autoclave. Second, the manufacturing concept is based on the use of existing commercial weaving equipment without the need for dramatic equipment modification. Composite structures with design envelopes controlled by cost and fatigue would benefit from this technology. These structures exist extensively in the energy and transportation industries. Composites are used in parts and structures such as shafting, wind turbine blade, trailers, bridges, equipment foundations, and springs. Return