A novel processing approach to produce microchannel embedded carbon-epoxy composites

Inspired by biological microvascular systems, microchannel embedded fiber reinforced polymer composites were developed to enhance the performance and reliability of aerospace composite structures by inducing self-healing, self-sensing and active-cooling capabilities. However, the creation of hollow channel network within composites largely depends upon the manufacturing technique, which not only influences the properties of channel and host structure, but also limits its use for a specific application. The aim of this study is to introduce a cost-effective, novel processing approach to produce microchannel embedded carbon-epoxy composites for a broader range of applications. The proposed approach essentially comprises of two steps of composite molding. In the first step, microchannels are first generated on the surface of a composite laminate during composite molding and later this composite laminate with microchannels is bonded with the other composite laminate in situ second step composite molding. The efficiency of the composite-composite joining was assessed through interlaminar shear and flexural testing. By applying this approach, carbon-epoxy composites embedded with microchannels of simple and complex shape, varying diameters and varying paths were fabricated, which can be potentially used in structural health monitoring, self-healing, lightweight heat exchanger, biological and chemical microreactors applications.