JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 49

Closing the loop for thermoplastic composites

Fig. 2: Awardwinning Tenax®
recycling solutions

Compression moulding
Toho Tenax has indicated compression
moulding as a potential production process
for non-structural aerospace parts made of
Tenax® Chips and Tenax® Crushed. Both
materials could be moulded in a short cycle
time without any additional processing to
produce high-strength complex parts in a
variety of sizes. Depending on the mould
system and final part properties, larger ma-

terial sizes are recommended as properties
improve together with longer fibre lengths.
The company's European partners, Greene,
Tweed & Co. GmbH and Cross Composite
AG, investigated the part manufacturing
process using Tenax® Chips and Tenax®
Crushed. Both materials showed excellent
compression moulding performance even in
comparison to virgin standard materials.
Recycled compound
The Tenax®-E Compound rPEEK CF30 is
a reinforced material combination made of
30% recycled carbon fibre by weight and
recycled semi-crystalline PEEK polymer to
offer high strength and stiffness performance
in injection moulding applications. This
compound has almost identical performance
to virgin standard materials in terms of tensile modulus, strength, elongation, viscosity,
chemical resistance and abrasion, and a very
low moisture absorption completes the
picture of this recycled material. The added
value of this compound results from the
combination of high-performance materials
with a 40-60% lower price than virgin carbon
fibre-reinforced PEEK compounds.
In conjunction with its partners - an OEM
aircraft manufacturer and the Sintex NP
Group - the company demonstrated that a
serial aircraft wing access panel can be manufactured to illustrate the performance of
the recycled granules. The Sintex NP Group
developed the part manufacturing process
based on Tenax®-E Compound rPEEK
CF30 and assessed the material's processa-

bility compared with today's standard virgin
materials within their production processes.
It showed that the best performance can
be achieved with full manufacturing and
design flexibility without any parameter
adjustments in the production chain. This
way, Tenax®-E Compound rPEEK CF30 can
reduce part costs significantly. Toho Tenax
recommends to run the injection moulding
process at a melt temperature of 380 to
400°C.
The closed-loop concept from production
remnants via Tenax®-E Compound rPEEK
CF30 to the final part won a JEC Award in
the Recycling category at the JEC Asia 2016
show on November 16th 2017 in Singapore.
Conclusions
The Toho Tenax group's aim is to recapture
the full value of the exclusive carbon
fibre-PEEK polymer material combination
and to establish a closed-loop concept for
its thermoplastic product portfolio. The
introduced recycled materials will offer
high performance at much lower costs than
today's virgin alternatives. Although they
were intended for use in the aerospace sector,
they might also be directed to non-aerospace industries due to their significantly
reduced cost. Together with an aircraft OEM
and partners in various part making and
application fields, Toho Tenax will further
investigate the reuse of residual materials.

No112 April - May 2017

More information:
www.tohotenax.com

/ jec composites magazine

Feature Aeronautics

complex 3D clips. In the first production step,
individual preforms are nested and cut out of
the original laminate (800 mm x 1,200 mm)
and heated to the processing temperature of
the polymer matrix. Then, they are quickly
stamp-formed in a metal mould in the second production step. Despite the endeavour
to arrange precise nesting and therefore an
optimum buy-to-fly ratio, a thin TPCL grid
will still appear.
In parallel to the Tenax® Chips, the material
concept also includes the implementation of
a recycling flow for Tenax® TPCL production
by-products resulting from the 3D stamp
forming process at the part makers. The
company plans to transform these by-products into Tenax®-E TPCL PEEK-HTA40
Crushed. This crushed CFRTP material
will be available in random sizes due to the
applied crushing/shredding process, but
downstream sieving stages could generate a
more homogenous raw material for further
processing steps. Once again, the material
grade can be optimized according to the
component requirements.

49


http://www.tohotenax.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017

Cover
Edito
Opinion: Civilian robotic
Contents
NEWS
In brief
Yachting
Strategy
Fabric
Agenda
BUSINESS
Additive manufacturing
Carbon
MANUFACTURING
Press
Repair
CNC
Natural fibres
Feature Aeronautics - Will the horizon stay clear?
Simulation
Software
NDT
Tooling
Self healing
Primary structure
Natural fibre
Recycling
Environment
Structures
SOLUTIONS
Sustainability
Sailplane
Lift
Construction
In the world
TECHNOLOGY
Nanomaterials
Thermoplastics
CFRP
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 68
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Opinion: Civilian robotic
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Yachting
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 11
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Strategy
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Fabric
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 17
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Ad IPC
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Ad JEC
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 19
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Carbon
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 21
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Press
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 24
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Repair
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - CNC
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Natural fibres
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 29
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 30
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Simulation
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 32
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Software
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - NDT
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 36
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Tooling
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 38
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 39
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 40
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Self healing
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 42
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Primary structure
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 44
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Natural fibre
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 46
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 47
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Recycling
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 49
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Environment
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Structures
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 52
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 53
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Sustainability
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Sailplane
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Lift
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Construction
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - In the world
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Nanomaterials
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 60
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 61
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 63
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - CFRP
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 65
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #112 - April/May 2017 - 67
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