High performance thermoplastic composite from flat knitted multi-layer textile preform using hybrid yarn

Modern flat knitting machines using high performance yarns are able to knit fabrics including the reinforcement yarns arranged differently into knit structures. Due to their improved mechanical properties, composites made from multi-layer knit fabrics show great potential in lightweight applications. This paper reports on the development of flat knitted multi-layer textile preforms for high performance thermoplastic composites using hybrid yarns made of glass (GF) and polypropylene (PP) filaments. Such textile preforms with different reinforcements were used to consolidate into 2D thermoplastic composites. Moreover, the mechanical properties of these composites were studied. The mechanical properties of 2D composites were found to be greatly affected by different arrangements of reinforcement yarns. The integration of reinforcement yarns as biaxial inlays (warp and weft yarns) is found to be the best solution for knitting, whereas tuck stitch shaped and unidirectional arranged reinforcements offer also promising application possibilities.