| RECYCLE | This project is in progress |
| Research and Development of PP Fibre Reinforced PP Thermoplastic Composite Materials, Processing Techniques and Applications |
|
Context Polypropylene (PP) is limited in its application at high levels of loading, and has to be reinforced to meet the high demands on stiffness and strength in automotive applications. Glass fibres are commonly used as reinforcing elements but they cause problems in recycling. Natural fibres, such as flax, hemp and sisal, have some ecological advantages over glass fibres, since they are renewable and can be incinerated. However, natural fibres do not have advantages with respect to mechanical recycling issues. Recently, polypropylene fibres have been used to reinforce PP and these so-called self-reinforced materials show great promise in terms of enhanced mechanical properties and recyclability. These materials are still in the infancy and much work is required to develop industrial-scale and low-cost processes, sandwich structures, joining and finishing technology. Current technology is inappropriate to lower volume sectors and applications that demand complexity, fast joining or finishing. Aims The overall objective of the project is to develop the processing, joining and finishing technologies that will allow the UK automotive industry to use self-reinforced polypropylene (SrPP). The specific project objectives are to: Develop non-isothermal forming techniques for SrPP structures. Assess and prove joining and finishing techniques for SrPP. Develop techniques to produce all PP based energy absorbent sandwich panels. Understand the effect of forming, joining and finishing on the materials and design criteria. Demonstrate recycling processes and techniques for SrPP. Dynamically evaluate 1 interior case-study and 1 exterior case study. Undertake a detailed technical, life cycle and economic analysis. Method The project has been structured to achieve the objectives by completing the following tasks and milestones: Tasks: Definition of material and process Enabling technologies Process development Design and analysis Application proving Dissemination and exploitation Project management Milestones: Defined finishing techniques (month 12) Selected process route and material (month 17) Recycling methodology in place (month 18) Validated test data (month 18) Completed case studies (month 24) Benefits The outputs from the RECYCLE will enable the UK automotive industry to exploit the benefits of SrPP. The environmental benefit of lighter-weight vehicles developed using this technology will reduce the per kilometre energy consumption, reducing emissions and urban pollution, whilst the total recyclability using existing techniques and collection routes will reduce landfill and help meet the ELV Directive. The energy absorption characteristics of the material and its structures will also improve the passive safety of both interior and exterior components. Additionally, if it can be demonstrated that medium to high volume SrPP structures can be made cost effectively for the price sensitive automotive industry, together with the identified technical and environmental benefits, then the materials and process will find widespread use in a range of other end user industries such as personal protective equipment (PPE). Participants BP Amoco Fabrics BI Composites Ltd Lotus Cars Ltd London Taxis International Ltd Trauma-Lite Ltd NetComposites Ltd University of Warwick |
|
|
|
|
|
|
|
|