Page 63 - Plastics News January 2017
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Cost effective lightweighting RPC Promens launches new
project to overmould carbon coating for HDPOE containers
fibre composite
Anew coating for HDPE containers from RPC
Surface Generation has devloped Cost effective Promens Industrial is able to provide a long term
lightweighting project to overmould carbon fibre barrier solution for solvent-based products for the
composite with thermoplastic. Carbon fibre processor, safer handling of a variety of chemicals. RPC Protect
Surface Generation, has started work on an 18 month is available for containers from 5 litres up to 25
R&D project to produce affordable lightweight carbon litres in size. A 30 litre container is also currently in
fibre components for the automotive industry. Backed development. The special barrier additive, a blend
by Innovate UK, the Rutland based firm will overmould of polyolefins and inorganic silicates, forms multiple
long-fibre reinforced carbon composites with a short-fibre strips on the inside of the container. RPC says
thermoplastic to produce a range of example coupons, importantly, unlike other plastic barrier solutions,
sub-element components and demonstrator parts. The used containers can be recycled if appropriate. The
advanced manufacturing techniques rely on its unique
PtFS process, which uses active thermal management availability of RPC Protect enables plastic containers
technologies incorporated in mould faces to adjust heating to be selected for an even wider range of products -
and cooling levels for each mould area and process stage in including extremely hazardous items that previously
real-time. PtFS is already being used by global automotive, could only be packed in metal - offering plastics’
aerospace and consumer electronics manufacturers traditional benefits of lightweight, easy handling and
to improve the quality and throughput of compression stacking, and reduced transportation costs. RPC says
and injection moulding applications and will be further its Protect containers have successfully undergone
developed over the course of the project. It makes up part drop, pressure and stacking tests, and their barrier
of a £2 million Thermoplastic Overmoulding for Structural properties have been proven to maintain their
Composite Automotive Applications (TOSCAA) project. performance for up to a year with no reduction in
It is joined by a consortium of firms led by SGL Carbon the effectiveness of the barrier. The product can be
Fibers and including Jaguar Land Rover. Ben Halford, chief specified across the majority of RPC Promens’ range
executive of Surface Generation, said: “The benefits of of HDPE containers, giving customers the flexibility
lightweight carbon fibre materials have been proven… but to create family ranges with both mono and barrier
are often uneconomic outside niche user cases. Surface versions, as well as the option for customised shapes.
Generation’s PtFS technology will extend the capability RPC Protect containers are FDA and EEC approved for
of thermoplastic overmoulding, to deliver the functional food use, and UN certified versions are also available.
benefits of carbon composites to a new class of cost
sensitive automotive components.
63 • January 2017 • Plastics News
