Recycling of thermoplastic composite tape edges trims through the thermoforming process

High performance carbon fibre thermoplastic composites are experiencing a strong growth in demand. These materials often come in the form pre-impregnated carbon fibre rolls. The impregnating resin being a thermoplastic polymer, the rolls can be stored at room temperature for an indeterminate time. The fabrication of the pre-impregnated thermoplastic composite generates wastes in the form of tape edge trims (TET). In effect, the edges of the pre-impregnated rolls need to be trimmed as they do not meet the quality requirements of the manufacturers due to the process not being properly controlled at the edges which can lead to variable tape thickness and fibre volume fraction. As the demand for these materials grows, so does the produced volume of TET. The goal of this project is to make use of these TET in the stamp forming process to manufacture parts of complex geometries. More specifically, we propose to manufacture parts from hybrid materials, using virgin continuous carbon fibre/thermoplastic plies and TET. Hybrid preforms (blanks) will be produced and stamp-formed. Our objectives include the characterization of the material, including the flowing ability of the TET, and the development of the process for this particular hybrid/recycled material.

Faculty Supervisor:

Martine Dubé

Student:

Partner:

Teijin Carbon America, Inc

Discipline:

Engineering

Sector:

Manufacturing

University:

École de technologie supérieure

Program: