An electrostatic powder spray process for manufacturing thermoplastic composites

Abstract Manufacture of thermoplastic composites is expensive because of the difficulty of impregnating the resin into the fibers. Powder processing shows great promise as an impregnation technique for cost‐effective manufacturing. This paper discusses an electrostatic powder spray impregnation technique that uses glass fibers. A geodesic fiber spreader is used to spread the fibers locally in the region of maximum powder deposition. A negative corona electrostatic spray gun is employed to charge and direct the powder for coating both sides of the spread fiber tow. The process has been used to impregnate glass fibers with poly(aryl ether ketone ketone) powder. The effect of the powder mass flow, corona voltage, and fiber tow velocity on powder deposition has been investigated. Particle image velocimetry is utilized to determine particle velocities. Compression molded panels have been produced and tested in three point bending.