A scientific view on composite inlays in running shoes: The influence of epoxy crosslink density on bending and fatigue properties

This study highlights the need for a deeper understanding of the structure-property relationships of carbon fiber reinforced thermosets applications, whenever considered as a functional part for running footwear. This is done, investigating the static and dynamic flexural properties of three different epoxy resins in prepreg-based carbon fiber composite laminates, varying the glass transition temperature (Tg). In this way, the inherent morphology of the resin was correlated with the fatigue properties of the laminate, which is crucial for the design of composite stiffening inlays for running shoes. First, it was shown that the crosslink density and aromatic content of the resin, which correlates with Tg, drastically affect the compressive strength of the matrix and are therefore crucial for the static and dynamic flexural properties of CFRP. Increasing the Tg from 147 °C to 269 °C leads to stiffening of the resin and thus increased resistance to fiber buckling, resulting in improved bending stiffness, flexural strength, bending angle, overall fatigue strength and thus durability of CFRP plates for running shoes. Moreover, the percentage of fibers in the loading direction can be considered as the main factor affecting the flexural properties of the laminate. Here, a quasi-isotropic stacking order leads to an increased bending angle but to a decrease in bending stiffness, flexural strength and fatigue strength compared to a unidirectionally reinforced composite due to a high load bearing capacity of the 0° fibers. This knowledge creates a basis to bridging the gap between composite material and biomechanical sports science for future work.