Altuglas composite resin solutions are acrylic formulations. Through the use of the same low pressure processes and equipment used today to produce thermoset composite parts, the formulations lead to the production of (meth)acrylic thermoplastic composites reinforced by fibres. The resulting parts are said to show properties similar to those made with thermoset materials while presenting advantages of post-thermoformability and recyclability. The resin solution was awarded with the Jec Innovations Award in the Thermoplastics category.
Michel Glotin at the Arkema booth at Jec Europe, next to a demonstration part realised with the awarded Altuglas composite formulation
Plastics: Congratulations, you received the Jec Award in the Thermoplastics category for your Altuglas composite thermoplastic resin that processes like thermosets. What is the most innovative feature of this development?
Glotin: The main feature is that the thermoplastic composite can be processed on existing standard thermoset equipment. So little or no capital investment is necessary. It behaves like a thermoset while keeping the advantages of thermoformability and recyclability. The formulations can be used to produce (meth)acrylic thermoplastic composites reinforced with fibres with low-pressure processes. The resulting (meth)acrylic thermoplastic composite parts offer new possibilities for composite-composite or composite-metal assemblies.
Thermoset composite demo part (photo: Arkema)
Plastics: Can you tell us something about the formulation and the processing?
Glotin: Altuglas Composite RT300 meth(acrylate) resin is a low viscosity, accelerated resin, styrene-free. Through the use of the same low pressure processes used in thermosets, these formulations lead to the production of (meth)acrylic thermoplastic reinforced composites. To reinforce the material, you can use continuous glass, carbon or flax fibres, depending on the application.
The resin can be used for resin transfer moulding (RTM), vacuum assisted resin infusion (VARI) and other closed mould processes. Typical production cycle times are 0.5 to 1.5h when curing at room temperature or around 15min when curing at 80°C mould temperature.
Plastics: What applications did you have in mind when developing the new formulation?
Glotin: We are targeting two types of application: aesthetic parts like bonnets for trucks or for machinery where the surface quality is a relevant concern. And secondly, structural parts where the mechanical strength is the key criterion. As far as the aesthetic parts are concerned, we entered into a collaboration with MVC Componentes em Plasticos, a Brazil-based company. Together with PPE we developed a large demonstration part using a RTM process at room temperature.
For the structural parts we have a collaboration with Chomarat and 3B. We managed to reach mechanical strengths similar to those of classical epoxy/glass thermoset composites at similar reinforcement volume fractions.
The awarded (meth)acrylic based chemical formulations behave like a thermoset while keeping the advantages of thermoformability and recyclability. (photo: Arkema)
Plastics: What sort of post-processing jobs are involved?
Glotin: For visible applications, you just need a gel coating or a thermoplastic film which is placed in the mould and thermoformed to the part. It is an ABS-PMMA film which provides a very nice finish. Furthermore, it is a faster process than gel coating and opens new decorative possibilities plus eliminating the need for an adhesive layer between the composite and the surface layer.
Plastics: How do you estimate the cost aspect associated with this innovation for the processor?
Glotin: It is difficult to estimate a price for finished components. As far as thermoplastics are concerned, we are at the lowest possible cost level. When it comes to the process costs, we are looking at process costs that are typical for thermosets. I think that, in the final analysis, our materials could perhaps be a cheaper bet than a thermoset, but there are very many factors to be taken into account here.
Plastics: Thank you very much, Mr Glotin.
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