Next generation intermediate materials
TORAYCA® Prepreg ET40

TORAYCA® Prepreg ET40 is an innovative prepreg which simultaneously provides high mechanical properties and excellent formability. ET stands for Extensible and Transformable by 40%. The superior levels of formability can achieve complex shaping by compression molding with equivalent mechanical properties to conventional UD prepreg. Those features enable to drastically reduce cycle time and improve proactivity for a large volume applications such as automotive parts.

TORAYCA® Prepreg ET40

Processing Technology

ET40 is made by introducing slits into UD prepreg in a controlled manner, creating a type of unidirectional SMC material in which fiber bundles are regularly arrayed in the same direction. This method allows for the consistent and regular flow of the bundles during the molding process and therefore results in the ability to be shaped into complex shapes, such as rib and deep-drawing, while maintaining a homogenous laminate structure due to its extensible and transformable nature. As a result of specific slitting patterns, ET40 is able to achieve the equivalent surface appearance, modulus and over 80% of the strength of UD prepreg.

Special slit pattern to be installed onto UD prepreg.

Homogeneous Laminate structure

Solutions

ET40 is made by introducing slits into UD prepreg in a controlled manner, creating a type of unidirectional SMC material in which fiber bundles are regularly arrayed in the same direction. This method allows for the consistent and regular flow of the bundles during the molding process and therefore results in the ability to be shaped into complex shapes, such as rib and deep-drawing, while maintaining a homogenous laminate structure due to its extensible and transformable nature. As a result of specific slitting patterns, ET40 is able to achieve the equivalent surface appearance, modulus and over 80% of the strength of UD prepreg.

3D shaping by compression molding

TORAYCA® Prepreg ET40 for 3D Shaping by Compression molding

Reinforcement for metal structure

4ply [0]4 16ply [0]16
UD prepregSpring back
ET40Multiple layers can be draped simultaneously, no spring back

* FAW = 150g/m2

Mechanical Propertied sfter stretch mold (Isotropic flow)

In quasi-isotropic stacking sequence, ET40 has no declining in tensil modulus, in spite of the slits introduced into each ply.

Decreases of tensile strength and impact strength of ET40 are only 20% approximately.

Decreases of tensile strength and impact strength of ET40 are only 20% approximately.

Applicable Prepreg

Any type of UD prepreg and resin system can be applicable for ET40.

3 types of rapid cure resin system are available for compression molding with ET40.

3 types of rapid cure resin system are available for compression molding with ET40.