Morphology Lightweight Approach - Challenges of Processing Self-Reinforced Sandwich Structures

In the context of resource depletion and climate change, conventional fiber reinforced plastics play a crucial role in achieving climate goals, particularly in lightweight applications. However, sustainability challenges arise from their hybrid composition, which complicates recycling due to issues like fiber shortening during mechanical recycling and the presence of critical substances in chemical recycling.
An alternative is the use of mono-material or self-reinforced composites, where both the fiber and matrix are derived from the same polymer, enhancing recyclability. Yet, these materials often exhibit lower stiffness compared to traditional fiber reinforced plastics.
To address this limitation, weight-specific properties must be taken into account. One effective lightweight design method is the sandwich approach, which combines various material morphologies - such as high tenacity fibers, bulk material, and foam - all made from the same polymer. This method optimizes the lightweight potential of a single material, effectively balancing performance and sustainability. However, processing these materials presents significant challenges, such as fiber relaxation and core crushing, that must be addressed. The presentation will cover the latest advancements in self-reinforced composites and recent research on their processing.