Fiber Volume Fraction Influence on Fiber Compaction in Tapered Resin Injection Pultrusion Manufacturing

Liquid resin is injected into the tapered injection chamber through the injection slots to completely wetout the fiber reinforcements in a resin injection pultrusion process. As the resin penetrates through the fibers, the resin also pushes the fibers away from the wall towards the centerline causing compaction of the fiber reinforcements. The fibers are squeezed together due to compaction, making resin penetration more difficult; thus higher resin injection pressures are required to effectively penetrate through the fibers and achieve complete wetout. Fiber volume fraction in the final pultruded composite is a key to decide the mechanical and/or chemical properties of the composite. If the fiber volume fraction is too high, more fibers are squeezed together creating a fiber lean region near the wall and fiber rich region away from the wall. Also, the design of the injection chamber significantly affects the minimum injection pressure required to completely wet the fibers. A tapered injection chamber is considered such that wetout occurs at lower injection pressures due to the taper angle of the injection chamber. In this study, the effect of fiber volume fraction on the fiber reinforcement compaction and complete fiber wetout for a tapered injection chamber is investigated.