sampe_long_beach_fibrtec

Advances in Multidirectional Thermoplastic TowpregMichael R. Favaloro, CompositeTechs Robert Davies, FibrtecMingfu Zhang, Johns Manville Fiberglass

Content

• Introduction– Why thermoplastic v's thermoset prepregs– Manufacturing processes for continuous fiber TP

prepreg– FibrFlex3D product and process description

• Product Development Results• Discussion • Summary and Conclusions

IntroductionWhy Thermoplastic Prepreg?• Thermoplastic Composites Provide Significant

Advantages v's Thermosets – Improved Performance, Processability and Cost

• However, the Composites Industry is committed to Thermoset Composites– >50 years experience – Tech depth, capital equipment, and database is

extensive, as well as resistance to change• The Use of Thermoplastics Have Begun to

Accelerate Industry Uptake– Lower cost materials and processes lead to adoption

IntroductionContinuous Fiber TP Prepreg Processes

• Most TP Prepreg Processes Require Conversion of Resin to Solution, Powder, Film or Fiber, which adds cost

Source: Wakeman, M.D., Månson, J-AE, Design and Manufacture of Textile Composites, Chapter 6, 2005.

• The FibrFlex Process Utilizes Thermoplastic Resin Pellets as Supplied– No Resin Conversion = low cost– No Tape Slitting, further reducing cost– Straight Line, Simple Process

The FibrFlex TP Prepreg results in a 20%+ savings in product cost

IntroductionFibrFlex3D Process Description

• Simple Process + Low CAPEX = Low Cost Product • Tailorable for many resin/fiber/chopped fiber combinations• Allows for rapid product development• Other fillers can also be incorporated

IntroductionFibrFlex3D* Product Description

• FibrFlex3D Combines Continuous Fiber & Chopped Fiber Reinforcement with a Thermoplastic Matrix

• The net result is a – Tougher composite– More conformable, ease of processing– Chopped Fiber reinforces bosses and smaller features that

are formed in the final molding process• Combines Continuous Reinforcement and Injection Molded

features• Eliminates machining/bonding of bosses and other features while

still incorporating reinforcement in those areas

* Patent pending

IntroductionFibrFlex3D Product Description (cont’d)

• Continuous reinforcement is carbon, glass, basalt, etc.• Most thermoplastic matrices can be used• The matrix can Incorporate chopped fiber, particulates,

nanofibers, etc.• Unsaturated core provides flexibility, ease of handling

– The end product is easily consolidated to a void free laminate

Continuous Reinforcement

Resin/Chopped Fiber

Unsaturated Tow


• Short reinforcement improves interlaminar, toughness, and interface with continuous fiber

• Short reinforcement also flow into bosses, molded features• Other particulates can replace short reinforcement as appropriate

– Electrical Enhancement– Density Management– Etc

Continuous Fiber

Chopped Fiber


Tow surface


Burn off oven results

Product Development Results

Material vol % wt %Density (g/cc)

PPS 49.6 34.6 1.35E Glass, 1200 tex 47 61 2.51E Glass chopped 3.43 4.4 2.51

FibrFlex3D measured 1.935calculated 1.935

• PPS E-Glass FibrFlex3D Components Have Been Fabricated

Final Part Porosity is NegligibleWet Out is Excellent, Debulk is Complete

Results (continued)

• Chopped Fiber/Matrix Successfully Formed the Threads in this G/PPS FibrFlex3D Commercial Application

Molded-In Inserts

Preliminary Mechanical Property Data

Several versions of Toray PPS resin were evaluatedTest data courtesy of Johns Manville Fiberglass

0-90 Data BaselinePanel# 1B-1 2B-1 3B-1 4B-1 5B-1 150813-01Continuous Fiber Wt % 64.7 64.4 62.4 62.7 63.5 67.7Chopped Glass % by wt 1.2 2.2 3.5 3.1 3.4 3.6Base resin melt flow rate 410 410 410 1090 1850 very low

Flex Strength mPa 536 333 426 363 339 647 Modulus gPa 20.4 11.8 15.1 12.2 11.5 28.4 Strain % 2.74 3.15 3.06 3.20 3.24 2.4

Tensile Strength mPa 395 256 352 266 261 328 Modulus mPa 30400 17800 23700 27300 23100 5330 Strain % 1.54 1.78 1.69 1.43 1.44 7.4

Interlamianr Shear mPa 33.5 156.9 75.0 33.5 83.5 183

Unnotched CharpykJ/m2 59.4 67.1 67.3 51.4 48.9 43.1

Continuous Fiber Vol % 49.1 49.1 47.3 47.5 48.15 53

Mechanical Results Discussion• Incorporation of Chopped Fiber Reduces Continuous FV,

which Reduces Some Properties, BUT– Molded In Features Are Stronger with as-molded, un-cut reinforcement v’s

bonded or machined features.

• Correlations– Chopped Glass seems to improve interlaminar shear and Charpy impact– Tensile and Flex appear higher with higher viscosity resin, and with lower

chopped glass content– Test panel fabrication with FibrFlex3D resulted in quality laminates with

good flow.

• Follow on work is in process to address comparisons of – Same Resin Source and MW– Same Continuous FV– Carbon Fiber Reinforced Property Data

Summary and Conclusions

• FibrFlex3D is a Patent Pending enabling material that allows for low cost co-molding of Continuous Fiber and Discrete Thermoplastic Composites– No substantial drop-off of continuous

properties– Improved performance in reinforced features

• Future work will Investigate carbon fiber chopped filler as well as all carbon composites

Special Thanks to

• Toray – PPS Resin Support• Johns Manville – Reinforcement and

Testing Support • CompositeTechs LLC – Technical Support

Thank You

• For More Information Contact

Bob Davies, [email protected] Mike Favaloro, [email protected]

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