Covestro carbon fiber reinforced PC unidirectional belt applied to the first new lightweight tree climbing handle support piece

With support from the European Regional Development Fund (ERDF), Covestro has teamed up with Cato Composites BV and other companies to build a new tree-climbing support system. The system, led by Cato, is based on continuous carbon fiber reinforced thermoplastic (CFRTP) technology, using Reden BV simulation technology and Coxtron carbon fiber reinforced polycarbonate based Maezio® UD unidirectional strip and system processing technology. Create the first innovative lightweight structure CFRTP tree climbing support piece.

The CFRTP tree climbing support is made of Maezio® UD unidirectional tape material, which is not only extremely lightweight and durable, but also has high mechanical load-bearing performance to ensure the safety of tree climbing. In addition, the product can be manufactured efficiently in batches and is very cost effective.

Maezio® UD Unidirectional band

Key benefits of the CFRTP solution

■ Lightweight

In order to minimize component weight while maximizing performance, Cato was able to precisely match the application's loading path by stacking more than 50 layers of Coxtron Maezio® UD unidirectional tape and simulating calibration using a Reden BV structure with anisoanisotic fiber orientation. A thermoplastic carbon fibre tree climber made from these materials will weigh 50 per cent less than its aluminium counterpart. Lightweight components make climbing easier and more comfortable for the end user.

■ High performance

The Maezio® UD unidirectional tree climbing support is designed to be mechanically load-bearing in accordance with ASTM standards (including a maximum load-bearing capacity of 330 kg per foot).

■ Mass production

Maezio® UD Unidirectional tape can be adapted for mass production processes. Compared with thermosetting composites, the use of thermoplastic composites can be processed efficiently in a short period of time to achieve cost-competitive mass production, thus helping downstream customers to meet new market development opportunities.

■ Low waste

By combining with Cato's proprietary variable temperature compression molding (VCM) technology, Maezio® UD unidirectional strips minimize material consumption by precisely stacking the finished components directly from die-cut unidirectional strips, eliminating the finishing step and reducing production waste to near zero.

■ High recyclability

Thermoplastic composites are easier to recycle than thermosetting resins, thus reducing waste and landfill space. The use of composites instead of metals also offers the industry a higher potential for recycling composites.