Four different size distributions of preformed rubber particles were used to interlayer toughening carbon fiber composites. Prepregs were made using single pass impregnation with model epoxy resins containing the different preformed particle distributions at two concentrations. The particle distributions and average particle sizes were selected to investigate the effect on laminate structure and fracture toughness. It was found that the average particle size affected the interlayer formation in the cured laminate. A significant difference in the fracture toughness of the laminates was found due to a change in the particle size distribution, average particle size, concentration, and resultant laminate structures. In this study, it is shown that the particle size distribution must be taken into account when designing interlayer toughened composites so that mode I and mode II toughness can be optimized.
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