INLINE-IMPREGNATION - INDIVIDUALIZED PRODUCTION OF THERMOPLASTIC CONTINUOUS FIBER REINFORCED COMPOSITE PARTS

摘要

Continuous fiber reinforced thermoplastics (TP-FRP) are increasingly being used for lightweight construction parts due to their relatively short processing times and good mechanical properties as well as the potential to use further functionalization processes like injection molding or welding. Processes such as matched die forming or an integrated forming and injection molding process are already used for serial applications. However, these processes are still limited due to the limited diversity of thermoplastic prepregs available to the market which are essential for those forming processes. Therefore, a new process technology for the flexible production of lightweight parts has been developed at the Institute of Plastics Processing (IKV) at RWTH Aachen University, Germany. The developed Inline-Impregnation technique allows for processing cost-effective semi-finished products like dry reinforcing textiles, thermoplastics films or non-wovens. The impregnation step and forming step are integrated in a single process. Thus, users of the Inline-Impregnation technique are able to manufacture tailored thermoplastic composite parts with an optimized fiber orientation, adjusted fiber volume content and attuned fiber/matrix-combinations. In combination with a cost-saving mold technology, the technology offers an economic option for the production of prototypes and modular series as well as larger series with cycle times of approximately 3.5 minutes. Recent investigations at the IKV show that the mechanical properties and the achievable impregnation quality of inline-impregnated laminates match the properties of commercially available prepregs. This paper presents results of the research on the process technology (e.g. bending/tensile/shear properties, impregnation quality, process sequence).