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Long fiber thermoplastic composites demonstrate fiber dominant property improvements across the board. Tensile, flexural and impact properties are significantly elevated over analogous short fiber composites in a broad range of base resins. The excellent fatigue, creep and impact performance of long fiber thermoplastic composites provides the opportunity to utilize the materials as metal replacements.
How does the CPI's Advantage Process differ from other long fiber materials manufacturing processes?
Unlike injection or sheet molding processes that use precompounded thermoplastic composites that are shipped to the molder for conversion to finished goods, CPI's Advantage Process is in-line with the molding process. The process delivers a preform of bulk molding compound, at molding temperature, to be formed into a molded article by compression or compression transfer molding. Virgin thermoplastic resins, recyclates, colorants, additives and reinforcing fibers are compounded in synchronization with the demand established by the molded part cycle. The manufacturing steps associated with material compounding, cooling, warehousing, transportation and reheating to form a molded article are totally eliminated in the CPI process.
The majority of parts currently being produced by CPI's Advantage Process are based upon polypropylene and glass with a typical glass fiber loading of forty percent by weight. The custom designed gravimetric fiber feed systems used in the process deliver controlled amounts of one half-inch chopped fibers to the feed throat of the compounding extruder. The existing feeders are capable of handling chopped fibers up to one inch in length. Specially modified feeders can supply carbon, aramid or organic fibers, i.e., flax, kenaf and wood fibers to produce thermoplastic composites with a broad range of property and cost profiles.
Is it possible to use recycled thermoplastic resins using CPI's Advantage Process?
In-house regrind, post industrial and post consumer recyclates can be easily incorporated as feedstock for CPI's Advantage Process. Two single-screw extruders that are used in the process ensure that any recycled product form is completely homogenized prior to molding.
Is the Composite Products, Inc. manufacturing facility ISO or QS9000 registered?
CPI completed the certification process for ISO 14000, ISO 9002, and QS9000.
Economics are the most compelling advantage of in-line compounding. Like other processes for producing long fiber thermoplastic composites, the starting raw materials are plastic pellets, reinforcing fibers, and additives such as colorants, antioxidants, fillers etc. The economic advantage of in-line compounding is derived from the efficiency of the process and elimination of a "middle man".
Consider a typical formulation consisting of 60 weight percent polypropylene and 40 weight percent half-inch chopped fiberglass. For conventional and in-line compounding the average cost of raw materials at today's pricing is around $1.32/kilogram ($0.60/lb). Precompounded polypropylene long-fiber injection molding material sells for roughly twice this price in todays market, or approximately $2.64/kilogram ($1.20/lb), the difference being the compounders mark-up. Most of the mark-up is due to sales, administrative, business and profit costs involved with running the compounding business. By eliminating the middlemans mark-up on raw materials a savings of approximately $1.32/kilogram ($0.60/lb) will be realized.
Does CPI mold long fiber thermoplastic parts?
The main focus of CPI's business is the molding of parts at the CPI facility in Winona, MN. If it makes economic sense and the customer wishes to mold his or her own parts using CPI's Advantage Process, licensing of the process will be seriously considered. CPI's process technology has been developed and proven in over ten years of molding composite parts for automotive and industrial applications. Experience gained in producing well over three million molded parts has been used to continuously improve the capabilities of CPI's Advantage Processing Systems.
Do U.S. and foreign patents cover CPI's Advantage Process?
Composite Products, Inc. has applied for and been granted patent coverage in the United States, Canada, South America, Europe, and Pacific Rim countries.