Title: Advancements in Lightweight Reinforced Thermoplastic Composites: Versatile Flat Sheet Manufacturing and Applications

Authors: Liqing Wei, Ruomiao Wang, Mark O Mason

DOI: 10.33599/nasampe/s.24.0039

Abstract: Thermoplastic composites are valued for their lightweight, durability, affordability, and recyclability. This paper details the production of composite core panels comprising glass fiber (GF) and polypropylene (PP) through a wet-laid process, along with some typical properties of these panels. GF and PP are mixed in a slurry, and the mixture is wet-laid onto a former belt. The formed mat is subjected to a drying process, followed by lamination with nonwoven scrim skins on both surfaces, consolidation, and cutting to desired dimensions. The flat sheets are tested for physical (areal density, ash %, and density), mechanical (flexural, flatwise tensile, and skin/core adhesion), flame retardancy (FR), and acoustic properties. Incorporating non-halogen FR agent improved composite's ASTM E84 rating from Class B to Class A. Moreover, some durable decorative films are laminated, replacing one scrim layer and resulting in an A-surface panel. The decorative films exhibit acceptable adhesion to the core, passing the peel 180o test requirement. These composite flat sheets hold promise for applications in recreational vehicles, heavy trucks, building construction, and office furniture industry.

References: 1.H. Ning, N. Lu, A.A. Hassen, K. Chawla, M. Selim, S.A. Pillay. A review of Long fibre thermoplastic (LFT) composites. International Materials Reviews. 2020;65(3):164-88. 2.J. Thomason. The influence of fibre length and concentration on the properties of glass fibre reinforced polypropylene: 5. Injection moulded long and short fibre PP. Compos Part A: Appl Sci Manuf. 2002;33(12):1641–1652. 3.J. Hartikainen, P. Hine, J. Szabo. Polypropylene hybrid composites reinforced with long glass fibres and particulate filler. Compos Sci Technol. 2005;65(2):257–267. 4.J. Thomason. Mechanical and thermal properties of long glass fiber reinforced polypropylene. Polypropylene: Springer. 1999;2:407–414. 5.H. Xu, P.T. Evers. Lightweight reinforced thermoplastic composite with improved formability. SPE ACCE, Novi, MI, September 4-6, 2019. 6.L. Wei and L. Scott. Poly-coated paper laminated onto lightweight reinforced thermoplastic composite panel via in-line lamination. In proceedings of CAMX - The Composites and Advanced Materials Expo, Dallas, TX, October 16-18, 2018. 7.L. Wei, R. Wang, and M.O. Mason. Light-weight reinforced thermoplastic composites with new design for recreational vehicles. In proceedings of CAMX - The Composites and Advanced Materials Expo, Anaheim, CA, September 23-26, 2019. 8.L. Wei, R. Wang, and M.O. Mason. In-line laminate decorative thermoplastic composite panel. May 10-21, 2021. 9.R. Wang and Y. Yang. Flame retardant and acoustic light-weight reinforced thermoplastic panel. In proceedings of CAMX - The Composites and Advanced Materials Expo, Orlando, FL, September 11-14, 2017. 10.Z. Yu, R. Wang, Y. Yang, M.O. Mason. Prepregs, Cores and Composite Articles including Synergistic and Compounded Flame Retardant Materials.; US Patent Application US 15/397,933 11.J. Singh, M. Kumar, S. Kumar, S.K. Mohapatra. Properties of Glass-Fiber Hybrid Composites: A Review. Polymer-Plastics Technology and Engineering. 2017;56(5), 455-469. 12.A.E. Tiuc, O. Nemeş, H. Vermeşan, and A.C. Toma. New sound absorbent composite materials based on sawdust and polyurethane foam. Composites Part B: Engineering, 2019;165, 120-130. 13.R. Wang. Acoustic and flame retardant light-weight reinforced thermoplastic composite. In proceedings of SPE-ANTEC, Orlando, FL, May 7-9, 2018. 14.L. Wei, R. Wang, and M.O. Mason. Reinforced Thermoplastic Containing Recycled Cardboard Fibers for Recreational Vehicle Applications. In proceedings of SPE Annual Technical Conference Virtual, 2020.

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000039

Pages: 11

Price: $22.00