Thermoformable Composite Panels FlexForm （可作热压成形的复合面板FlexForm）.pdf

Thermoformable Composite Panels From automotive to aerospace, thermoformed composites are growing exponentially, offering short cycle times, tailored properties, recyclability and lower cost. Thermoformable composite panels are thermoplastic materials—e.g. polypropylene (PP), nylon 6, polyetherimide (PEI), polyphenylenesulphide (PPS)—reinforced with some type of fiber, and then supplied to customers as solid sheets, which are then thermoformed into shaped structures. Although many of these products are also sold as prepregs, the materials covered in this article are preconsolidated panels. There are also stand-alone core materials which can be thermoformed; however, this article will only explore panels, one of which is a unique thermoformable, in-situ foamed sandwich material. Reinforced Thermoplastic Composites The use of thermoplastics in composites offers a range of attractive features: • Short manufacturing cycles (typically 2 minutes or less). • Increased toughness and impact resistance. • Post forming possibilities such as corrections and forming in multiple steps (e.g. edge close-outs and then folding). • Unlimited shelf life, no VOCs and reduced issues with waste and material handling. • Recyclability, both during manufacturing (recycling scrap) and after service life. These features are driving huge growth. According to the market research report “Opportunities in Continuous Fiber Reinforced Thermoplastic Composites 2003-2008”, published by E- Composites (Grandville, MI), “the market for continuous fiber reinforced thermoplastic composites has experienced … a global growth rate of 105 percent in the last 5 years. The growth rate in 2002 was 93 percent.” The report continues, “Historically, continuous fiber reinforced thermoplastic composites were used in niche applications in the aerospace and defense markets. But in recent years, the market has exploded in automotive, sporting goods, transportation, industrial and other