MANUFACTURING PMMA THERMOPLASTIC PREPREG USING A LAB-SCALE SOLVENT PREPREG TREATER

Thermoplastic composites are in increasing demand in the automotive and aerospace industries due to their increased recyclability, reducing high energy waste typical with thermoset-based composite materials. Alternative methods to manufacture thermoplastic prepreg are required to meet growing demand and reduce startup costs of developing thermoplastic prepreg manufacturing infrastructure [1]. In this research, poly(methyl methacrylate), PMMA, thermoplastic prepreg was manufactured using a lab-scale, solvent prepreg treater [2]. Liquid methyl methacrylate monomer and oligomer, Elium C595E, was used as a matrix in manufactured thermoplastic prepreg using fiberglass, flax, and linen fibers. Prepreg treater processing parameters and polymerization catalysts were initially determined on a benchtop scale as proof of concept. Manufacturing was successfully upscaled to a lab-scale treater for medium-scale production of prepreg material. Prepreg matrix degree of polymerization was measured using DSC, and resin content was measured using a combination of TGA and areal weight averages. The performance of the prepreg was quantified using composite tensile, short beam shear, and ASTM flexural bar standards. The above test results show that Elium C595E resin can be used effectively in a solvent prepreg treater system to manufacture PMMA-based thermoplastic composite material at a large scale.