Modeling of filtration through multiple layers of dual scale fibrous porous media

Abstract Functionally graded composites exhibit properties within the material that vary gradually without a recognizable boundary. One technique to manufacture functionally graded polymer composites is by liquid composite molding process. In this process, structural fabric layers are stacked in a closed mold and resin is injected into the mold. Particles may be added to the resin to tailor the properties of the final product. The structural fabrics typically consist of yarns or bundles of thousands of micron size fibers woven, stitched, or knitted together, which gives rise to a bimodal distribution of pore sizes; the larger pores in between the bundles and smaller ones within the bundles. The filtration process that takes place during infusion alters the flow resistance of the porous media and complicates the impregnation process. In this study, a vacuum‐assisted resin transfer molding (VARTM) process‐based approach is presented that enables functional grading in composites to obtain a desired distribution in properties. A model of the filtration phenomenon is proposed to predict the concentration distribution of particles within the dual scale fibrous porous media infused under a constant pressure drop. The approach uses Darcy's law and accounts for lowering of the permeability value due to the particle entrapment in the available pores. Experiments are conducted and the concentration of the particles in the fabric is measured. The results compare well with the predictions despite many assumptions made in the model. Nondimensional analysis and parametric study reveals the influence of critical parameters on the final particles concentration gradient. POLYM. COMPOS. 27:570–581, 2006. © 2006 Society of Plastics Engineers