Title: Upcycling Waste Plastics for High-Value Continuous Fibre Reinforced Composites Applications

Authors: Ilse ten Bruggencate, Marco del Vecchio, Ferrie W.J. van Hattum

DOI: 10.33599/nasampe/s.22.0722

Abstract: Typically, recycled plastics have reduced properties with a larger scatter, compared to their virgin counterparts, often resulting in a lower market value. By using plastic waste streams as a matrix in fibre reinforced thermoplastic composites (TPCs), these products can be manufactured more cost-effectively, potentially with properties comparable to virgin TPCs. This research looks at producing continuous fibre reinforced composite tapes made from recyclates (rTapes). In a previous study, Polypropylene (PP), Polyethylene (PE) and Polyester (PET) waste streams were characterised in terms of rheological properties and contamination effects. The overall mechanical behaviour of the rTape UD-composites and overmolded rTapes was investigated (ref [1]). After the material characterisation, a demonstrator, a typical automotive part, is selected consisting of overmolded rTape inserts. In this demonstrator three types of inserts are combined: pultruded stiffeners, 3D printed frame and weave. The different insert production processes are investigated, and the final demonstrator, containing the rTape inserts overmolded with recycled plastic, manufactured. This resulted in a first-time 100% recycled plastic overmolded TPC demonstrator, with the addition of tailor-made continuous fibre reinforcements on load-bearing locations. As such it shows the potential of plastic recycling in thermoplastic composites manufacturing, with added value and potential lower CO2-footprint and cost reduction.

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000722

Pages: 15

Price: $30.00