Introduction
Polyphenylene Sulfide Carbon Fiber Reinforced Plastic (PPS CFRP) is an advanced composite material that combines Polyphenylene Sulfide (PPS) with Carbon Fiber Reinforced Plastic (CFRP) to achieve exceptional performance in high-temperature and mechanically demanding or harsh environments. PPS is an engineering plastic known for its superior heat resistance and chemical stability, while CFRP offers lightweight, high-strength performance. The integration of these two materials has positioned PPS CFRP as a cutting-edge composite material across multiple industries.
In this column, we explain the fundamental properties, advantages, and applications of PPS CFRP.
Basic Properties of PPS?
PPS (polyphenylene sulfide) is an engineering plastic that boasts outstanding stability under elevated temperatures and chemically corrosive conditions. These advantages make it well-suited to diverse industrial applications. PPS properties include:
– Heat Resistance: PPS can be used at temperatures above approximately 260°C and is considered to have very high heat resistance.
– Chemical Resistance: PPS exhibits excellent resistance to strong acids, alkalis, and oils, maintaining structural performance in harsh chemical environments.
– Mechanical Strength: It provide high tensile strength and rigidity, delivering mechanical performance comparable to many metals.
Basic Properties of CFRP
Carbon Fiber Reinforced Plastic (CFRP) is a composite material consisting of carbon fiber embedded in a resin matrix. It is recognized for its extremely high strength and lightweight characteristics. CFRP properties include:
– High Strength and Rigidity: The exceptional rigidity and high strength-to-weight performance of CFRP offer multiple distinct advantages in aircraft and automotive components, sporting equipment, and other performance-critical applications.
– Corrosion Resistance: CFRP demonstrates superior resistance to corrosion compared to metals, enabling long-term and stable performance with minimal deterioration.
– Excellent Fatigue Resistance: CFRP performs reliably under repeated loading and high-stress conditions.
Properties of PPS CFRP
The combination of PPS and CRP integrates and enhances the complementary advantages of each material, resulting in the following PPS CFRP characteristics:
– Excellent Performance in High-temperature Environments: The superior heat resistance of PPS allows PPS CFRP to perform stably in elevated temperatures where conventional CFRP materials are often limited. This makes it ideal for use in engine components, and structures exposed to high-temperatures and other harsh conditions.
– Lightweight and High Strength: The lightweight properties of CFRP combined with the added structural strength of PPS enable production of extremely strong and lightweight components, making it ideal for use in aircraft, automobiles, and precision equipment.
– Chemical Resistance: PPS’s inherent chemical resistance combined with CFRP’s high mechanical strength facilitates improved durability and structural performance in harsh chemical environments.
– High Rigidity and Wear Resistance: PPS CFRP demonstrates exceptional resistance to mechanical loading, friction, and deformation due to mechanical wear.
Applications of PPS CFRP
The distinct and advanced properties of PPS CFRP have accelerated its adoption across diverse industries. It is gaining particular traction in the following areas:
Automotive Industry
PPS CFRP is being leveraged for weight reductions in engine components, exhaust systems, and auto body sections that required high resistance to heat and mechanical wear. The balanced combination of weight reduction and structural strength contributes to improved fuel efficiency and driving performance.
Aerospace Industry
Within the aerospace industry, PPS CFRP is applied to internal and structural aircraft components—including aircraft frames, wing structures, and engine-adjacent component, where strict weight and thermal requirements must be met.
Electronics
PPS CFRP is also being leveraged in electronic equipment components and connecting parts that operate under high temperatures or environments prone to abrasion.
Precision Instruments
In precision instruments and measuring equipment, PPS CFRP has become the material of choice for components that require low-density, high-mechanical strength, superior resistance to abrasion to ensure accuracy and long-term reliability.
PPS CFRP Manufacturing Methods
PPS CFRP is processed using established CFRP manufacturing methods. These include the following:
– Prepreg Molding: Carbon fiber sheets are pre-impregnated with PPS resin and then molded through controlled heat and pressure. This method is well-suited for high-precision components and complex geometries.
– Compression Molding: Compression molding is typically employed for molding high-precision PPS CFRP structures that require rapid and efficient production.
– Injection Molding: Injection molding is used to create molded structures from a compound mixture of PPS and carbon fiber. This method is typically employed for producing high-precision structures in large quantities.
Summary
PPS CFRP is an advanced composite that integrates exceptional heat and chemical resistance with high strength-to-weight performance, driving innovation across a broad spectrum of industries, including aircraft, automobiles, and precision instruments. Its distinctive properties significantly improve the performance of structures and components operating in harsh environments and conditions, thereby enhancing overall product quality. PPS CFRP is expected to expand into an even broader range of industrial applications as technological developments continue to advance and emerge.
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ABOUT UCHIDA - 55 years since our founding
We leverage a wealth of technical expertise as a CFRP molding and processing manufacturer using FRP, GFRP, and CFRP materials. We offer a one-stop solution, encompassing design, analysis, manufacturing, secondary processing, assembly, painting, quality assurance, and testing.
UCHIDA's equipment
We have cutting-edge equipment to ensure that we can address even the most advanced challenges of our customers.
DMG森精機 - VS1000/40/2050
X軸：2,050mm（ストローク） ／ Y軸：1,000mm ／ Z軸：600mm ／ テーブル作業面：2,250×1,000mm
ASHIDA MFG Co., Ltd.
Autoclave Oven 2
Size : Ø1,150x1,000mm / Operating temperature : at normal temperature - 400℃ / Design pressure : 2.0Mpa (maximum working pressure) / Vacuum system : back suction system / Vacuum units : 5
ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000x6,000mm / Operating temperature : at normal temperature - 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ - 0.99Mpa/cm²） / Boost pressure accuracy : 0 - 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10
Oven
Size : W1,000xH1,000xD1,000mm / Temperature range : Environmental Temperature +20 - 300℃ / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 45min less / Vacuum system : back suction system / Vacuum units : 10
ESPEC CORP.
Temperature & Humidity Chamber
INSTRON
Static Universal Testing Machine 5985
Oven
Size : W7,000xH3,000xD2,000mm / Temperature range : Environmental Temperature +20 - 300℃ (Max) / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 60min less / Vacuum system : back suction system / Vacuum units : 10
NEO
X axis : 4,000mm (stroke) / Y axis : 2,000mm / Z axis : 1,200mm / C axis : 0° - ±270° / B axis : 0° - ±110° / Table working place : 4,000x2,000mm
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3Dプリンター | Markforged
Painting booth
Various painting, and clear finish is done in dedicated painting booth
Adhesion, Finishing, Coating Room
Finishing process, such as trimming, drilling, and bonding, surface treatment of the molded product type and is done in a private booth
Toshiba Matrixeye EX (Ultrasonic flaw detector)
Matrix-Arrey : 32
AMETEK CREAFORM Metra
SCAN750 Elite (3D scan)
Olympus Corp.
Inverted Microscopes
Oven
Size : W450xH450xD450mm / Temperature range : Environmental Temperature +20 - 650℃ / Temperature elevation capability : Environmental Temperature+50 - 650℃/120min less
Cutting Plotter Table working place : W1,500xL3,500mm
SHIMA SEIKI MFG., LTD
Cutting Plotter
KUKA
Robot
Krauss Maffei
Epoxy resin injection machine Resin 60L ／ Hardener 25L
Krauss Maffei
630t Press machine Height total 5,200mm ／ Length max 1,500mm ／ Width max 1,200mm ／ Whole cycle time per component part 240sec
DMG森精機 - NV5000B/40
X軸：1,020mm（ストローク） ／ Y軸：510mm ／ Z軸：510mm ／ テーブル作業面：1,320×600mm
Big sized clean room
JIS B 9920 cleanliness class maximum concentration (Pcs/m³） / Class 5 : 100,000m³ / Capacity : m² (16,000x16,000mm) 760m² (16,000x16,000x3,000mm) / Temperature and humidity condition : Temperature : 23℃±3℃, Humidity 65% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Temperature -5℃ during winter, Humidity 40% less
CAD / CAM
CATIA V5 : 2 / THINK DESIGN : 1 / MASTER CAM : 4 / Other 3D/CAD : 3 / Other 2D/CAD : 5
Markforged - 3D Printer
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