Spread Tow Technology for Ultra Lightweight CFRP Composites: Potential and Possibilities

Tow spreading is one of the-state-of-the-art technologies that have been used recently in the composites industry. An understanding of spread tow technology and the possible production of high performance carbon fibre-reinforced polymer (CFRP) composites are discussed in this chapter. The development of ultralightweight composite material referred to as tow-spreading technology is presented, whereby a conventional 12k carbon fibre tow is thinned by increasing the tow width from 5mm to approximately 25mm, thereby reducing the weight per unit area by approximately 500%. Using the tow-spreading technology, sheets of unidirectional (UD) and/or woven fabric can be produced. For example, an aerospace thermoplastic grade film and nonwoven Polyphenylene Sulphide (PPS) was used to stabilise and impregnate the spread tows (woven/UD), converting it into a partially consolidated CF/PPS prepreg, and consequently laminates and demonstration parts are made. The properties of spread tow laminates are compared to conventional tow laminates. The spread tow materials exhibited better fibre packing, lower level of crimp, lower void content and improved mechanical properties.