Mansfield based Imhotep has developed a one-stage manufacturing sytem for production of extruded continuous composite profiles using a conventional thermoplastic matrix.
The manufacturing technology, which has been developed over the past three years and was part funded by a SMART award from the DTI, uses a single extruder to both impregnate the core of continuous fibre reinforcement and to apply a 100% resin content surface layer in one step. This results in a very stiff thermoplastics composite profile with a high gloss surface appearance similar to a conventional extruded profile.
According to Imhotep, the technology has been developed to avoid the use of precursor materials in traditional production of thermoplastics profiles which has meant that the products have in the past been too expensive for many potential applications.
The new profiles also offer the advantage over conventional pultruded products that they can be post-formed thermally. Welding techniques can also be used in fabrication or for fitting of end caps or other items.
At the present time, the technology can be used to manufacture circular-section profiles ranging from 8mm to 11mm diameter containing upto around 55% by volume of continuous fibre reinforcement. However, the developers say that it can be applied to a wide range of cross-sections.
In addition, Imhotep says that the new technique is applicable to a much wider range of raw materials than traditional thermoplastics composite processors. In particular, the new system opens the way for the use of high levels of recycled material in the polymer matrix. Imhotep sees its technology having great potential in recycled plastics applications, where the mechanical properties of the polymer often need to be raised.
Imhotep can currently offer reinforced recycled PP composite rods from stock in 8 and 11mm diameters, and can design and manufacture profiles in other shapes and materials on a contract basis. Alternatively, users vcan take the manufacturing technology on board under a licence arrangement. The company's technology package includes design of tooling, commissioning of the production equipment and staff training- prices start from £20,000 plus a 2% royalty of sales.
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Reproduced from PRW February 11 2000
Imhotep Ltd
Unit 6, Eco Court
Latimer Way
Sherwood Energy Village
New Ollerton
Newark
NG22 9QW
England
Tel: +44(0)1623 863452
Fax: +44(0)1623 863652
e-mail: enquiries@imhotepcomposites.co.uk