ProUD | Unidirectional tape and tow based preassemblies for hybrid processes

The ProUD project researches in an integrated way the entire chain for hybrid production processes using unidirectional tape and towpreg-based pre-assemblies for large and complex products. 

Context

The properties of thermoplastic composite materials combined with the availability of fast and precise processing and assembly options, make thermoplastic composites an interesting candidate for high-performance parts in several industries. Originally developed for high-performance applications in the aerospace industry, thermoplastic composite are now used in increasingly geometrically complex and large products and in large-series production such as in the automotive industry.

Objective and results

In the ICON-project ProUD, the research focus lays on micro-reinforced thermoplastic unidirectional tapes and tow prepegs for use as local reinforcing material in window profiles, thermoplastic beer crates and palettes. The hybrid processes aimed at are overmoulding and overextrusion with localized application of GFRP UD reinforced materials.

Sioen will develop glass fibre-reinforced thermoplastic unidirectional tapes. Deceuninck will overextrude these glass fibre-reinforced PVC tapes into PVC window profiles, whereby the tapes will be incorporated as local reinforcements (instead of corrosion sensitive steel bars) on the weakest parts of the window profile. This allows the use of less reinforcement material and the design of more complex profiles that will comply with the increasingly stringent insulation norms. DW Reusables will overmould the micro-reinforced thermoplastic tapes and more complex structures derived thereof into thermoplastic crates and palettes in order to increase the reusability factor and the staple height in the warehouses, resulting in more circular materials.

KU Leuven, as a basic research partner, will build up new knowledge on tape processing, automation and modelling in support of the company developments. Sirris, as a research partner, will develop new processing lines for the tow prepeg production and the hybrid processes (overextrusion, overmoulding) and will support the companies by the implementation of these processing techniques.
The ProUD project will thus resolve major material, process, design and end-of-life challenges - at the fundamental and applied level - so that leading companies along the materials development, processing and application chain can successfully start up commercial operations.

Funding

Reference

VLAIO ICON PROUD “Unidirectional tape and tow based preassemblies for hybrid processes” (speerpuntcluster SIM)