Project: Fast pultrusion process based on a novel anionic catalytic system for the production of advanced polyamide composite profiles

Our project aims at developing a fast and continuous process to manufacture fibre reinforced thermoplastic composites profiles. This process known as “pultrusion” was initially used in combination with thermoset. Two CO reasons could be proposed to explain this situation:_x000D_· thermoplastic resins have a very high intrinsic viscosity ( > 100 Pa.s ) as compared to thermosets that strongly limits the impregnation of the fibres, _x000D_· techniques which have been investigated do not lead to competitive solutions due to the large numbers of processing stage and limited performances of the final product ( poor surface aspect, limited fibres content, poor impregnation, limited to simple shape profiles, … )_x000D__x000D_CQFD Composites has recently demonstrated the industrial feasibility of a liquid reactive method to produce highly reinforced thermoplastic pultruded profiles._x000D__x000D_This approach generates many key advantages over conventional “polymer melting” techniques :_x000D_· the use of primary raw materials ( monomer and large tow low cost fibres ),_x000D_· an unmatched impregnation with a very high fibre content ( up to 85% in weight ),_x000D_· a potentially outstanding bonding between the fibres, _x000D_· a drastic reduction of production sequences through a one step process,_x000D_· customised properties economically achievable within the polymerisation course by straight forward addition of fillers,_x000D_· a perfect surface aspect straight from the pultrusion die._x000D__x000D_Nevertheless, the reach of this promising technique into large volume markets is reduced mostly by the intrinsic speed of the process._x000D__x000D_Our objective within a 3 year time frame is to develop a fast and economical process for the production of thermoplastic composite profiles based on PA6 matrix ._x000D__x000D_Fulfilling this objective will require us to develop a fast catalytic system that shall also induce an excellent fibre-matrix adhesion in order to limit the use of expansive mats or tissues that are usually embedded into each composite profile to generate transversal strength. _x000D__x000D_Based on our actual achievements our R&D program which includes theoretical studies, lab scale and industrial testing on a pilot pultrusion line is organized as follow:_x000D__x000D_· new catalytic system development to improve process speed without compromising the polymer performances and the process stability,_x000D_· fibre-matrix impregnation and adhesion enhancement at elevated speed to get rid of expansive mats or tissues normally required for transversal strength._x000D_· new pultrusion machinery to allow a continuous and automatised handling of the resin appropriated to the novel catalytic system._x000D_· process parameters versus composite properties study to fully benefit from our process ability to generate a range of low cost customized composite materials (molecular weight, cristallinity, fibres contents, copolymers 6-12,..)._x000D__x000D_Expected market applications are very diverse but big shares will relate to the Building Industry with key applications in concrete reinforcement in alternative to corrosion treated steel rebars for sea side environments, window profiles and thermal solar collectors frames in alternative to aluminium profiles with much better thermal insulation performances and outstanding UV resistance. ( cf section 2.3)_x000D__x000D_Strong expertise in the field of pultrusion, fibre-matrix interface and anionic polyamide chemistry are the foundations of our consortium composed of two complementary R&D SME companies:_x000D__x000D_· KATCHEM ( Czech Republic) a R&D chemical company strongly specialized in the field of catalytic systems for anionic polymerisation of lactams with integrated production capacity._x000D_The Czech Republic is a leading country in the anionic polymerisation science._x000D__x000D_· CQFD Composites (France) , a R&D and process oriented company skilled in the field of reactive pultrusion with a CO focus on polyamide 6._x000D__x000D_KATCHEM has already developed specific catalytic systems for targeted applications in the RIM ( Reaction Injection Molding ) markets._x000D_CQFD Composites has already developed its own propriety continuous process to manufacture composite profiles by reactive thermoplastic pultrusion with integrated industrial pilot pultrusion line._x000D__x000D_To meet the strong requirements of the Building market, both in terms of cost and technical performances, KATCHEM and CQFD Composites are combining their knowledge to bring up a new process tuned for the fast and economical production of highly reinforced polyamide composite profiles. _x000D__x000D__x000D_

Acronym	CATAPULT (Reference Number: 4774)
Duration	01/04/2009 - 31/12/2012
Project Topic	Development of a fast continuous process for the production of thermoplastic composite profiles based on the benefits of a unique proprietary reactive thermoplastic pultrusion technique combined with a novel anionic catalytic system for polyamides
Project Results (after finalisation)	New fast and stable catalytic system for anionic polymerization of 6-caprolactame suitable for technology of pultrusion and for technology of casting polyamide-6.
Network	Eurostars
Call	Eurostars Cut-Off 2

Project partner

Number	Name	Role	Country
2	CQFD Composites	Partner	France
2	Katchem Ltd.	Coordinator	Czech Republic