Development of a process chain for the production of transparent fibre reinforced thermoplastic composites

In this work a process for the production of a transparent endless flat E-glass fibre reinforced composite material with a PC/PCT blend matrix is developed. The material has a high strength and low weight and exceeds the properties of laminated glass. The E-glass fibres are opened by an ethanol bath and spread using a newly developed air vibration spreader, achieving a maximum spreading degree of 3.5. The transparent portion of the heat pressed sample produced makes up 96.5 %. In addition, 92.6 % of the glass fibres are parallel to the sample surface, which is crucial for an undisturbed beam path through the component. The consolidated material achieves a tensile strength of 221 MPa at a tensile modulus of 12 GPa and a bending strength of 309 MPa at a flexural modulus of 13 GPa. With regard to optical properties, a transparency of 80.4 % is achieved. Overall, the tech-nical feasibility is proven based on these results, as a technically competitive material is realized. The economic aspects are analysed by a process cost analysis, which is then compared with the manufacturing costs of laminated glass. This Shows the economic feasability of the newly developed process. A market analysis is carried out and refined by means of a business case in order to prove the marketability of transparent FRPs. The market analysis identifies four possible applications of transparent FRP. In the automotive industry, transparent FRPs can be used as a pane material and in transparent columns, in aviation it can be used as window material in construction as glass facades. The market introduction of transparent FRP as panes in vehicle construction has the greatest economic potential in the present analysis.