“Prepreg Application Areas”

Thermosetting resin technology is mature and stable, making it the current mainstream matrix resin for prepregs. With breakthroughs in high-performance carbon fiber varieties and quality, as well as advancements in composite material structural design and manufacturing technology—especially with the emergence of domestically produced large aircraft—there will be a significant increase in the application of high-end prepregs in the aerospace field. The supply of prepregs in the aerospace sector will face a situation of high demand exceeding supply. In the new energy sector, the application of carbon fiber composite materials is relatively widespread in various secondary markets, such as wind turbine blades, photovoltaic polysilicon crucibles, and carbon fiber wrapped gas cylinders. Technological progress continues to increase its application share, making it a "ballast" driving rapid growth in carbon fiber demand. For example, the continuous development of the hydrogen energy industry has directly stimulated a large demand for carbon fiber wrapped gas cylinders for hydrogen energy vehicles, heavy-duty trucks, logistics vehicles, and even trains.

In the automotive sector, whether for traditional fuel vehicles or new energy vehicles, components such as body panels, frames, and drive shafts urgently require new materials to reduce weight and energy consumption. Carbon fiber is one of the best choices, with an increasing number of high-end new car models using carbon fiber composites from mainstream automotive manufacturers worldwide. The demand for prepregs in the automotive sector will continue to grow.

Trends in Prepreg Technology Development

With the rapid development of lightweight and high-speed aerospace applications, lightweight and flame-retardant rail transportation, and high-integration electronic and electrical systems, the requirements for composite materials' flame retardancy, mechanical properties, heat resistance, and dimensional stability are becoming more stringent. Consequently, prepregs will evolve in the following directions:

1.Development of New Thermoplastic Prepreg Systems: There are mainly two methods for prepreg preparation: solution impregnation and thermoplastic film impregnation. Currently, solution impregnation is predominant. This method involves impregnating fibers or fabrics with a resin solution, evaporating the solvent, and achieving the B-stage of the prepreg. The advantages of this method include low equipment investment, but the drawbacks are the difficulty in accurately controlling resin content and significant solvent evaporation, leading to environmental pollution. In contrast, the thermoplastic film method involves first forming a uniform and smooth film of molten resin, then combining the film with fibers or fabrics under certain temperature and pressure to produce a qualified prepreg. This process offers precise control of resin content, minimal volatile components, and no environmental pollution. Thus, developing new thermoplastic prepreg systems is becoming increasingly urgent.

2. Extended Room Temperature Storage: To reduce the manufacturing cost of advanced composite materials, in addition to various new technologies, an important aspect is the development of low-temperature, low-pressure curing resin systems. Extending the room temperature storage life of resins and prepregs without increasing curing temperatures would significantly lower the costs of storage and processing in advanced composite material manufacturing and use, eliminating the need for large cold storage facilities and modifications to existing molding equipment.

3. High Performance: The goals for new-generation aircraft include "lightweight, long life, high reliability, high efficiency, high stealth, high penetration, and low cost." This raises higher requirements for prepreg performance, such as lightweight, high strength, high-temperature resistance, ablation resistance, high mechanical strength, high dielectric performance, and designability. Additionally, as electronic products evolve towards higher speeds and frequencies, the demand for high heat resistance and excellent dielectric properties in prepreg materials for copper-clad laminates becomes increasingly important.