News in Composites
In the realm of innovation and sustainability, alternative materials play a crucial role. Composites, or composite materials, are materials made from at least two different substances to leverage the best properties of each. This allows for the tailored production of composites for specific applications. They are lighter yet stiffer than traditional materials, enabling the conservation of energy and resources.
The applications of composites are extremely diverse. In the automotive sector, composites help reduce vehicle weight and protect critical components like drive batteries. In construction, they are used for structural reinforcements. In boat building, composites are increasingly used for interior fittings and flooring. Even the photovoltaic industry utilizes composites as back panels for PV modules to reduce weight while simultaneously increasing strength.
Profol specializes in the production of glass fiber-polypropylene (PP) composites. The matrix is made of polypropylene (PP), while the reinforcing fibers made of glass bear the main load of the stress. Depending on the application, the fiber content ranges between 60% and 80% by mass. The combination of these two components results in a high-performance and lightweight tape, with unidirectional fiber orientation (UD-tape), our proUD-0° in 1.25m width on a roll. In an additional step, proUD-90° can be produced as roll goods, where the fibers run not in the machine direction, but across it.
From the combination of these 0° and 90° UD-tapes, organo-sheets are manufactured – Progano. The standard construction is a 10-layer combination of proUD-0° and proUD-90°. The respective sequence is predetermined by the application. In addition to Progano sheets, the production of ultra-lightweight sandwich boards is in focus. These consist of outer layers of UD-tapes and a core of polypropylene, such as honeycomb structures or various foams.
Our sandwich boards impress with very high stiffness and strength despite their very low weight. The variety of core materials allows for a wide range of properties to be achieved, thus covering the diverse requirements of various application areas. Our composite materials have a high strength-to-weight ratio and are up to 35% lighter than aluminum. This makes them ideal for applications where weight savings are of great importance.
In addition to stiffness and strength, they are also characterized by their high resistance to environmental influences. They are resistant to corrosion, chemicals, and weathering. The versatility of our composites allows them to be used flexibly. Thanks to their thermoplastic properties, they are easily deformable. Moreover, their production generates 66% less CO2 emissions than aluminum. Our composites are 100% recyclable and can be reused as raw material for fiber-reinforced injection molding at the end of their life cycle.
Innovation and progress are tackled at Profol. Our composite department shows how advanced materials can push the boundaries of what is possible and how these products can be produced cost-effectively in a continuous large-scale process. We are actively working on new developments in this exciting field and look forward to taking you on this exciting journey.
Fun fact: With our new saw, we can even build sandwiches twice as big. Click here to get even more insights into our composites production: YouTube
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