Development of thermoplastic composite sandwich panels using recycled PET foam

PROJECT COST:

341 268 $

PRIMA CONTRIBUTION:

154 068 $

PROJECT DETAILS:

Recycling not only mitigates carbon emissions but also reduces the demand for virgin raw materials, conserves energy, and minimizes environmental pollution. Among commonly recycled polymers, polyethylene terephthalate (PET) is a widely used thermoplastic resin applied in textile fibers, food and beverage containers, as well as thermoformed packaging materials. PET accounts for approximately 18% of global polymer production, ranking as the fourth most produced polymer worldwide. The recycling of PET and its conversion into value-added products has therefore become a critical priority. At present, certain manufacturers recycle PET by processing it into foam-based materials.

The research project, led by Prof. Mehdi Hojjati at Concordia University in collaboration with Prof. Annie Ross (Polytechnique Montréal), Prof. Ida Karimfazli (Concordia University), and the industrial partners Innovative Composite Products (I-C-P) and Armacel, focuses on the development of thermoplastic sandwich panels incorporating recycled PET foam. The primary objective is to integrate a newly engineered 100% recycled PET foam as the core material in sandwich structures and to assess its suitability for a range of industrial applications. Several design concepts, including corrugated core panels, will be developed and systematically evaluated. The investigation will encompass both mechanical performance (e.g., deflection and impact resistance) and functional performance (e.g., thermal and acoustic insulation). In parallel, the optimization of mechanical joining techniques for the panels constitutes another key component of the project. Ultimately, a detailed technical data sheet will be prepared for each product developed.

Innovative Composite Products (I-C-P) currently manufactures thermoplastic sandwich panels using glass/polypropylene composite face sheets combined with various core materials, while Armacell produces foams made from 100% recycled content. As a manufacturer of thermoplastic sandwich panels and an industrial partner in this project, I-C-P aims to establish itself in the market as a producer of sandwich panels incorporating recycled materials for diverse applications. The project will also enable Armacell to acquire new knowledge and expand the applications of its products. In addition, the project will contribute to the training of four doctoral candidates and two master’s students.