Development of a New Generation of Sustainable Towpreg Prepregs Made from Glass Fiber, Carbon, and Epoxy Applied in the Manufacturing of Type IV Pressure Vessels

• Grant number: 24/15623-8
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: June 01, 2025
• End date: May 31, 2027
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Nonmetallic Materials
• Principal Investigator: Michelle Leali Costa
• Grantee: Michelle Leali Costa
• Company: Forza Composites Tecnologia em Materiais Compósitos Ltda
• CNAE: Fabricação de artefatos de material plástico não especificados anteriormente ; Testes e análises técnicas ; Pesquisa e desenvolvimento experimental em ciências físicas e naturais
• City: São José dos Campos
• Associated researchers: Artur Cantisano

Abstract

The growing demand for efficient and safe solutions for the storage of pressurized gases, such as hydrogen and biomethane, is driving innovation in the manufacturing of pressure vessels. This project aims to develop a new generation of towpreg-type prepregs made from carbon fiber (CF) and glass fiber (GF) using vitrimer resins (DGEBA epoxy (diglycidyl ether of bisphenol-A) combined with 2-aminophenyl disulfide (AFD) curing agent). This polymer matrix system combines the properties of thermosets with the reprocessing capability of thermoplastics. These Type IV pressure vessels are essential for applications in sectors such as energy, transportation, and alternative fuel storage.Vitrimer epoxy resins are characterized by dynamic covalent bonds that can rearrange under certain conditions (usually heat), allowing the material to be recycled, repaired, and reshaped. Thus, the introduction of vitrimers offers several advantages over conventional epoxy resins, including reprocessability, repairability, and recyclability. Additionally, these resins allow storage at room temperature, eliminating the need for extremely low storage conditions (-18 ± 2)°C, which simplifies logistics and reduces costs. This addresses one of the main issues faced by current towpregs, which require refrigerated storage and have low tack and limited shelf life.Currently available commercial towpregs are expensive and present problems such as fiber slippage during processing due to low tack and an overly advanced B-stage cure, compromising their application. Moreover, the logistics of importing these materials involve complexities that can affect the quality and shelf life of the towpregs when they reach the national market.This project addresses these challenges by developing new materials and processes that ensure high quality and reliability of towpregs, meeting the demands of the national industrial sector efficiently and sustainably. The proposed innovation not only improves the properties of the towpregs but also facilitates their storage and transportation, promoting a more sustainable and economically viable solution for the manufacturing of Type IV pressure vessels. (AU)