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Coats launches hybrid fibre composite technology

News International-French

21 Mar 2016

Coats, the industrial thread manufacturer, is launching Synergex, a range of advanced composite fibres which can be processed into fabric form and then used to mould strong, but lightweight, parts for industries including automotive and aerospace.

Synergex has high levels of hybrid fibre integrity and performance. It can be processed into fabric form using many technologies including commingling and twisting. The carbon and nylon commingled yarn delivers a perfect balance between strength, weight, performance and also recyclability. The composite fibres can be embroidered directly into complex shapes and the final composite parts can be metal pressed.

The Synergex range has been developed by Coats Speciality using its state of the art carbon room at its Sevier site in North Carolina, US. It is dedicated to developing high performance composite constructions. From carbon processing units to aramid converting lines and fibreglass processing equipment, it is able to commingle and twist carbon fibres and various thermoplastic fibres. This enables the manufacture of flexible thermoplastic prepegs which produce advanced thermoplastic parts for the wind, automotive, aerospace and sporting goods sectors.

Coats announced its partnership with Elemental Group Ltd in the creation and development of the forthcoming Rp1’s sports car wheel arch which features Synergex. The wheel arch is made in four steps. The carbon fibre and nylon are woven together to create a single commingled yarn. The yarn is then embroidered into shape using a Tailored Fibre Placement (TFP) preforming process. Once the shape is precisely stitched, it is then placed in the machine mould and pressed to form the wheel arch. The parts can be finished to a high standard without the need to use resins or autoclave.

Peter Kent, Composites Director, Elemental, said: Choosing a material for the Rp1’s wheel arch presented a few challenges as it had to be lightweight, extremely robust and flexible to achieve the complex shape of the part. The properties of Synergex ticked all the boxes.’

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