Beijing OnlyTop Ultrasonic Spread Tow Tech Enables Thin-Ply Carbon Fiber Prepregs

Beijing OnlyTop Science and Technology Co. Ltd. has developed an ultrasonic-guided spreading process that transforms 12K and larger carbon fiber tows into ultra-thin prepregs and woven fabrics. This advancement enables more precise laminate design across various applications.

Producing thin-ply carbon fiber prepregs and fabrics involves more than reducing fiber areal weight. As the spreading width of carbon fiber tows increases, maintaining uniform fiber distribution, alignment, and mechanical integrity becomes challenging. OnlyTop's ultrasonic-guided process addresses these challenges by using ultrasonic waves to disperse individual filaments within the fiber tow, enhancing the uniformity of the structure.

Unlike traditional methods that use mechanical roller pressing or air negative pressure, the ultrasonic process employs cavitation effects. The collapse of bubbles during ultrasonic treatment generates localized shock waves that rearrange the dispersed filaments into a more uniform transverse structure. This process aims to increase the tow spreading ratio while minimizing fiber damage and preserving alignment.

The performance of this process is characterized by spread width, spreading uniformity, fiber damage degree, and fiber straightness. With this technology, OnlyTop produces thin-ply unidirectional carbon fiber prepregs with fiber areal weights ranging from 15-50 g/m². The woven thin-ply carbon fiber fabrics can achieve fiber areal weights as low as 52 g/m².

Recently, OnlyTop introduced color-plated spread tow fabrics that combine the mechanical performance of advanced composites with unique visual effects. These fabrics incorporate metallic characteristics through surface metallization, offering visual effects such as "silver shining through deep black" and "dazzling gradient turns." They are ideal for sports equipment and consumer electronics.

OnlyTop's thin-ply carbon fiber prepregs and fabrics are widely used in 3C structural components and sports equipment. Applications include smartphone underscreen brackets, hinges, battery compartment backplates, and speaker components. Thin-ply woven materials are also used in sports equipment like hockey sticks, pickleball paddles, beach paddles, carbon fiber bicycles, and protective helmets.

The core value of this technology lies in its ability to use thin, uniformly distributed plies for precise tailoring of laminate structures and component designs, beyond merely making composites thinner and lighter.