Injection Moulding with Continuous Local Reinforcements - IMCoLoR

Programme: H2020-EU.3.4.5.6. - ITD Systems
Topic: JTI-CS2-2016-CFP03-SYS-02-18 - Eco Design: Injection of thermoplastic reinforced with long bers (carbon, glass, Kevlar...) for scroll reinforcement
Call for proposal: H2020-CS2-CFP03-2016-01
Funding Scheme: CS2-IA - Innovation action
Grant agreement ID: 738131

Objective: In the IMCoLoR project the scroll of an air cycle machine is manufactured with an injection molding process with the local integration of continuous carbon ber reinforcements. The local reinforcements are placed along the main load paths in order to lead to a higher pressure and temperature resistance of the scroll than for a short carbon ber reinforced scroll as manufactured in CleanSky I. Consequently, with this method also new generation aluminum scrolls can be replaced by a thermoplastic scroll reducing weight and cost and preventing the need of hazardous surface treatments. For the local reinforcement of the injection molded scroll a two-step process will be developed. In a rst step, a 3D reinforcement structure from aligned pre-impregnated continuous carbon bers (Tape) will be manufactured with the AFPT process. A removable core system will be implemented as a tool for the lay- up process. This allows the load adapted design of the reinforcements. In a second step, the reinforcement structure will be xed inside an injection mold and will be overinjected by injection molding. The aim of the tool design is to enable a complete enclosure of the reinforcement structure. Therefore, the xation system is embedded into the injection mold and consists of movable xation elements that can x and release the reinforcement structure. When the xations are released they move backwards and are completely embedded in the mold. This enables the complete enclosure of the reinforcement inside the part without he buildup of gaps. The exact position of the reinforcement can be adjusted with the xations. Non-destructive and destructive test methods will be implemented in order to evaluate the processing quality and the mechanical performance of the part. A demonstrator will be manufactured with the developed technology and a nal evaluation of the process in terms of an industrialization of the process will be done.