| Research and Development of PP Fibre Reinforced PP Thermoplastic Composite Materials, Processing Techniques and Applications |
Project Description
Polypropylene (PP) is limited in stiffness and strength at high levels of loading and so has to be reinforced for the demands required of it in many automotive applications. Glass fibres or natural fibres, such as flax, hemp and sisal, are often used as reinforcing elements but they cause problems in recycling. Polypropylene fibres have been used to reinforce PP and these self-reinforced materials show promise in enhanced mechanical properties and recyclability. Much work is required to develop industrial-scale and low-cost processes for SRPP (self reinforced polypropylene), particularly in lower volume sectors.
The main objectives of the project were:
- To develop non-isothermal forming techniques and associated tooling for SRPP.
- To assess and prove joining and finishing techniques for self-reinforced PP.
- To develop techniques to produce all PP, energy absorbent sandwich panels.
- To understand the effect of forming, joining and finishing on the materials and design criteria.
- To demonstrate recycling processes and techniques for self-reinforced PP.
- To dynamically evaluate 1 interior and 1 exterior safety critical case study.
- To undertake a detailed technical, life cycle and economic analysis.
Results - What Happened Next?
The project developed processes for forming, joining, sandwiching, painting and recycling SRPP. The effect of processing conditions, such as temperature and forming pressure, on mechanical properties was assessed. Tooling was used to identify the forming limits of SRPP and strain analysis was used to assess the strain limits. Two case study components were designed, manufactured and tested. A prototype SRPP Lotus Elise Front Access Panel was 57% lighter than the current production part and passed environmental testing.
The project conducted an in-depth sustainability assessment for SRPP in automotive applications. SRPP has good environmental and social performance during material and
component manufacture when compared with traditional composites. Modelling indicated that the SRPP parts were cost-neutral compared to current production solutions. SRPP offers good potential for fuel savings, thereby reducing CO2 emissions and running costs for a vehicle.
Following this successful project, partners are now exploiting the results and have begun applying the technology in the automotive sector and other industries.
Lead Partners
NetComposites Ltd
Participants
Lotus Cars Ltd
London Taxis
International Ltd
Propex Fabrics
Trauma-Lite Ltd
BI Composites Ltd
University of Warwick
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