Title: Development of recyclable self-reinforced polypropylene parts for automotive applications

Authors: Brendon M. Weager, G.R. Bishop, A.C. Black, N. Reynolds, M.W. Pharaoh, G.F. Smith, J. Rowe, D.E. Riley, M. Birrell, P. Donaldson

Addresses: NetComposites Ltd., Tapton Park Innovation Centre, Brimington Road, Chesterfield S41 0TZ, UK. ' NetComposites Ltd., Tapton Park Innovation Centre, Brimington Road, Chesterfield S41 0TZ, UK. ' NetComposites Ltd., Tapton Park Innovation Centre, Brimington Road, Chesterfield S41 0TZ, UK. ' Warwick Manufacturing Group, University of Warwick, Gibbet Hill Road, Coventry CV4 7AL, UK. ' Warwick Manufacturing Group, University of Warwick, Gibbet Hill Road, Coventry CV4 7AL, UK. ' Warwick Manufacturing Group, University of Warwick, Gibbet Hill Road, Coventry CV4 7AL, UK. ' Materials Engineering, Lotus Cars Ltd, Hethel, Norwich NR18 8EZ, UK. ' Propex Fabrics UK, Braeside, Straightacres Lane, Bradford BD10 8AT, UK. ' BI Composites Ltd, P. Box 161, Royston, Hertfordshire SG8 0WX, UK. ' Trauma-Lite Ltd, 6 Canary Way, Agecroft Commerce Park, Swinton, Salford M27 8AW, UK

Abstract: Self-Reinforced Polypropylene (SRPP) offers competitive mechanical properties, higher recyclability and reduced weight compared to glass fibre-reinforced PP, making it attractive to the automotive industry. The technologies required to produce finished automotive components from SRPP have been developed during a UK-based project, called RECYCLE and supported by the UK government. Forming processes and associated tooling systems have been developed based on matched tool stamping. Suitable joining techniques have been identified, including adhesive bonding and welding and all-PP sandwich panels have been produced and tested. Automotive finishes, such as exterior paint and interior fabrics, have been applied successfully. The technology has been demonstrated in two automotive case studies – an exterior panel for the Lotus Elise and an interior cover panel. Significant weight savings have been identified compared to current production parts and the technology has been shown to be sustainable from environmental, social and economic viewpoints.

Keywords: self-reinforced polypropylene; SRPP; thermoplastic composites; automotive composites; automobile industry; vehicle design; lightweight; forming; joining; sandwich panels; painting; recycling; sustainability; matched tool stamping; automotive panels; adhesive bonding; welding; finishing.

DOI: 10.1504/IJVD.2007.013645

International Journal of Vehicle Design, 2007 Vol.44 No.3/4, pp.293 - 310

Published online: 10 May 2007 *

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