In this study, we propose a low-cost and high-cycle manufacturing process for carbon fiber-reinforced plastic (CFRP) high-pressure hydrogen tanks in hydrogen fuel cell vehicles. The manufacturing process consists of the production of a thermoplastic prepreg using an in situ polymerizing acrylic resin, a preform manufacturing process using the obtained thermoplastic prepreg, and a low-pressure resin transfer molding (RTM) process using the preforms. An acrylic resin was designed using a REDOX radical reaction assisted by UV radical polymerization to achieve high-speed prepreg manufacturing. Rheological measurements of the unreacted in situ polymerizing acrylic resin suggested the attainment of suitable prepreg manufacturing conditions. Strand tests and microdroplet measurements revealed the successful fabrication of prepregs with good interfacial adhesion between the resin and CF.
