JEC World additional news (updated March 9, 2016 at 6:00 PM)
For JEC World 2016 (March 8-10, 2016, Hall 5A – Booth H46) Chomarat is unveiling its new glass fibre reinforcement ROVICUT™, which stretches to hug the curves of pipes and conduits that need to be rehabilitated, without sacrificing mechanical performance. The Group will also present a new Sports & Leisure application for its carbon C-PLY™ line. BASF will be presenting innovative composite solutions and an Enhanced cooperation between JEC Group and AZL is announced. In addition Revology, a start up company, presents its Concept Chair made of sustainable material
Chomarat presents two innovations at JEC World
For JEC World 2016 (March 8-10, 2016, Hall 5A – Booth H46) Chomarat is unveiling its new glass fibre reinforcement ROVICUT™, which stretches to hug the curves of pipes and conduits that need to be rehabilitated, without sacrificing mechanical performance. The Group will also present a new Sports & Leisure application for its carbon C-PLY™ line
ROVICUT™, THE FIRST STRECHABLE WOVEN REINFORCEMENT FOR RENOVATING CURED-IN-PLACE PIPES (CIPP). THE ADVANTAGES: REDUCED WEIGHT AND THICKNESS FOR FASTER, MORE COST- EFFECTIVE INSTALLATIONS.
The Chomarat Group developed ROVICUT™ in collaboration with Reline Europe, a leading manufacturer of sleeves for the in situ repair of pipes.
Trenchless technology using cured-in-place pipes (CIPP) consists of manufacturing sleeves from glass fibre reinforcements, coating them with resin, installing them inside a damaged pipe system and curing them under ultraviolet light. The pipes are renovated without opening up a trench, so there is no noise disturbance or dirt, and road traffic is not perturbed. “ROVICUT™ is unique in the market, because the sleeve thickness is optimized to make it more lightweight, thus making it easier to handle and install, with faster UV cure. So there is a considerable economic advantage,” says Chomarat Sales Manager Marlène Berthouze.
ROVICUT™ was designed specifically for Reline’s new Alphaliner 1800 line dedicated to large- diameter pipes. Because it is stretchable, ROVICUT™ takes the exact shape of the worn pipes, increasing the mechanical performance without adding too much thickness to the pipe interior.
WITH C-PLY™, DYNASTAR LOWERS THE WEIGHT OF ITS “MYTHIC 87” SKI LINE BY 26%, FOR EQUIVALENT PROPERTIES.
Launched in January 2016, the “Mythic 87” line of skis uses Chomarat’s C-PLY™ multiaxial carbon reinforcements. These innovative backcountry skis were first developed for competitive skiing, but are now available for all skiers.
The structure of C-PLY™ carbon reinforcement is optimized in terms of angles, ply weight and fibre alignment, so there is a perfect balance between strength and responsiveness, between high performance and weight. This makes for a more lightweight yet powerful ski.
“Thanks to the use of C-PLY™, we lowered the weight of the skis by more than 25%, making it more comfortable for skiers and providing higher downhill performance. The combination of Dynastar know-how and the high-tech nature of C-PLY™ makes the ski the lightest one we have ever produced!” explains Dynastar Product Manager Franz Marsan.
BASF presents innovative composite applications at the JEC World Composites Show
At the “JEC World Composites Show”, which runs from March 8 to 10, 2016 in Paris, BASF will be presenting innovative solutions for composite applications made of polyurethanes, epoxy resins and thermoplastics. This trade fair is considered one of the world’s most important exhibitions for specialty materials
From an award-winning demonstrator to mass production: Composite materials for serial production with different technologies
For lightweight construction in automotive engineering, BASF is showing various examples of current and future technologies with composite materials based on polyurethane systems and thermoplastics. The technology demonstrator for mountain bike handlebars illustrates how complex hollow components in automated high-volume series can be produced at competitive costs. Jointly developed by KTM Technologies, H2K Minerals, Teufelberger Composite, and BASF, it won the prize in the RTM category for this year’s JEC World Innovation Award. Known as “Cavus” the project gives an integrative view of the entire process chain. The demonstrator was produced in the HP RTM (high-pressure resin transfer molding) process with BASF’s polyurethane reactive resin Elastolit® R. This compact reactive resin has a wide processing window at short demolding times as well as outstanding mechanical properties including very good fatigue strength and high damage tolerance.
Thermoplastic composite materials with glass fiber or carbon fiber-reinforced tapes are a key element of Ultracom®, the integrated system from BASF for continuous fiber-reinforced components in car body and chassis. In addition to semi-finished products and overmolding compounds, the system also offers customers support from the concept phase via component design to simulation and processing including parts testing in order to enable efficient serial production. With thermoplastic unidirectional tapes component strengths can be adjusted in targeted ways to reduce weight even more while achieving higher quality and greater production efficiency. This is illustrated by a number of demonstrators at the stand.
Already a serial part: the roof module with a honeycomb sandwich structure made in a single processing step with the polyurethane foam system Elastoflex® E. The roof module in the standard model of the new smart fortwo consists of a paper honeycomb core and two glass fiber mats that have been impregnated in a spray process with low-density, thermally activated Elastoflex® E 3532 and pressed with a solid-color class A film.
BASF expands portfolio of PU pultrusion systems
Pultruded parts manufactured from Elastocoat® C have proved themselves in terms of fiber-matrix adhesion and dynamic properties. In addition, the pulling forces required in production have now been significantly reduced in order to allow high pultrusion speeds. Furthermore, a system with low viscosity is now available for the production of carbon fiber pultruded parts with a high fiber content.
Together with Fiberline Composites A/S in Denmark, BASF had already demonstrated the high performance level of PU pultrusion systems for components in the construction of rotor blades for wind turbines. Thick-walled profiles to integrate threaded bushings in the root section of the blade are made of Elastocoat® C.
Epoxy resin systems and PET (polyethylene terephthalate) structural foams in rotor blades
The Baxxodur® epoxy resin systems and Kerdyn® PET (polyethylene terephthalate) complete BASF’s range of solutions for the wind industry. They address the trend towards larger parts and comprise a variety of production processes. The Baxxodur® system offerings for composites are based on BASF’s comprehensive portfolio of amine-based curing agents that are unmatched in the industry. Kerdyn® PET (polyethylene terephthalate) structural foam unites good mechanical properties with wide process compatibility. Thanks to its high temperature and chemical resistance, it adds stability to rotor blades.
Ultra-light utility poles made of Elastolit® withstand extreme loads
BASF presents a new type of very strong and wind resistant utility pole made with BASF’s polyurethane system Elastolit®. The technology was already proven in China and is now available in Europe as well.
These poles based on a filament winding technology are much lighter and at least 2.5 times more wind-resistant than the commonly used concrete utility poles for medium voltage grids. Due to their very lightweight – a 12 metre composite pole weighs only 250 kg – they are easy to install and no heavy equipment is needed when erecting the poles. The bending strength of the new type is at least 2.5 times higher compared to concrete poles which allows long distances between the single poles of up to 120 meters.
BASF’s Performance Materials division encompasses the entire materials know-how of BASF regarding innovative, customized plastics under one roof. Globally active in four major industry sectors – transportation, construction, industrial applications and consumer goods – the division has a strong portfolio of products and services combined with a deep understanding of application-oriented system solutions. Key drivers of profitability and growth are our close collaboration with customers and a clear focus on solutions. Strong capabilities in R&D provide the basis to develop innovative products and applications. In 2015, the Performance Materials division achieved global sales of EUR 6.7 billion.
Sabic with fibre-reinforced thermoplastic tapes by acquisition
Sabic – one of the world’s leading petrochemical companies – has expanded its growing portfolio of innovative material solutions with the recent acquisition of a majority stake in Fibre Reinforced Thermoplastics, B.V., which is based in Lelystad, The Netherlands.
Sabics’s Fibre Reinforced Thermoplastics (FRT) business, specializes in the production of engineered thermoplastic, fibre-reinforced unidirectional (“UD”) tapes. The tapes can be used across a wide variety of industries, ranging from building and construction, to transportation and energy.
“This acquisition will enable SABIC to develop new thermoplastic products, processes and design solutions to help our customers take full advantage of the unique light weighting opportunities offered by composites,” said Ernesto Occhiello, EVP Specialties, SABIC.
“At SABIC, we engage with our customers to develop advanced products that support their specific needs and help them realize their ambitions,” said Andrey Turchin, Head of SABIC’s FRT business. “Our innovative UDMAX™ composite tapes complement SABIC’s existing range of thermoplastic solutions for customers striving to build smaller, lighter and stronger components that meet stringent industry standards,” he continued.
UDMAX™ tapes are made using a unique proprietary HPFIT™ technology, which quickly and precisely enables the spread and combination of thousands of glass or carbon fibres with a polymer matrix. As a result, the tapes have a high density of fibre, high quality fibre impregnation in the resin matrix, minimal void content and fewer broken fibres. They can be used to form composite materials that can in turn be used to manufacture components with superior performance to alternative materials, such as laminates and moulded parts.
Sabic will be exhibiting at the JEC in Paris, 8-10 March 2016. We looking forward to meeting you at our stand – Hall 5A, L 73.
Revology unveils its concept chair at JEC
The New Zealand Design-Tech start-up will unveil the design of its first creation, the elegant and refined Revology concept chair at JEC World (8-10 March 2016, Paris Nord Villepinte) at the Revology stand (Hall 5A/F30) and on the Sustainable Planet (Hall 6/N6). A reinterpretation of the legendary 1850 bistro chair, it is also the first chair to be made out of flax-fibre tubes and bio-based materials
“JEC World is the leading exhibition in the composite sector. That’s why we decided to unveil our Revology concept chair there in an exclusive preview. It is a perfect illustration of the design freedom that composite materials offer. The result of a real technological feat, the chair will be made using the most innovative of nature-friendly processes and materials. With this object, we are continuing to push the technological envelope to reach for new, green, design-worthy goals!” explains Revology CEO Alex Guichard.
The play of contrasts between transparency and the raw natural material makes the Revology concept chair an object that will break the mould of international design. Its organic feature is an essential element in the brand’s DNA.
Using composite materials for the chair has the advantage of making it lightweight, versatile and strong, with an elegant design that time will not alter. “Composites are used in the aviation industry and luxury sectors, so they tend to be seen as materials that are too technical or inaccessible. With Revology, we want to show that they are also materials that we can introduce into our everyday world. We want to make them attainable for the general public: sustainable design, high-end product but reasonably priced!” concludes Alex Guichard.
Enhanced cooperation between JEC Group and AZL
Mrs Frédérique MUTEL, JEC Group President and CEO and Dr Michael EMONTS, Managing Director of AZL, the competence network for excellence in lightweight production, are very happy, after a first successful cooperation, to announce the extension of their partnership agreement which has started in 2015.
The purpose of the partnership is to jointly promote actual developments and insights regarding integrative lightweight production technology at JEC World to illustrate their benefits to the Composites Professionals for the development of Knowledge and the enhancement of their Networking.
This partnership consists in the organization of a shared technological program over the 3 days of the trade show. Most recent scientific developments will be presented by AZL and its 8 partnering institutes of RWTH Aachen University in the framework of the so-called “Composites in Action – JEC Group in partnership with AZL”. Also, a guided visit of related exhibiting AZL partner companies at JEC World 2016, as well as a dedicated area for AZL and its partnering institutes showcasing their innovative products and live demos will be important assets of this partnership. Innovations along the whole composite value chain are presented by AZL and the Institute for Textile Technology (ITA), Institute of Plastics Processing (IKV), Fraunhofer Institute for Production Technology (IPT), Welding and Joining Institute (ISF), Laboratory for Machine Tools and Production (WZL), Fraunhofer Institute for Laser Technology (ILT), Institute of Automotive Engineering (IKA) and Institute of Structural Mechanics and Lightweight Design (SLA).
Frédérique MUTEL, JEC Group President and CEO says: “JEC Group is thrilled to renew this agreement with AZL. Intense connections between Technology and Industry are vital in the development of composites. JEC Group encourages such connections globally and locally. With AZL participation, our audience will benefit from the newest technological results and best practice approaches in the field of composites manufacturing. The synergies and expertise that we put in common will undoubtedly be a great value added to the Composites community”.
ITA presents its textile value chain from fibre to component at JEC
The Institut für Textiltechnik (Institute for Textile Technology) of RWTH Aachen University (ITA), Germany, exhibits at the booth of AZL and 8 partnering institutes of RWTH Aachen University “Composites in Action – Composites 4.0 – JEC Group in Partnership with AZL“, booth no. C80 in hall 6. There ITA presents its expertise based on the textile value chain from the fibre to the component with the following main exhibits:
1. Pressure vessel produced on a Multifilament Winding Machine „MFW-48“
The MultiFilament Winding Machine „MFW-48“ was developed and built by Murata Machinery Ltd., Japan. It allows high productivity of preforms for applications in composites and features very good mechanical properties in fibre direction. MFW-48 is the first machine of its kind in Europe which shall be installed at ITA prospectively.
In the MFW process, a large number of bobbins are processed simultaneously. Reinforcement fibres, e.g. Carbon fibres, are deposited on a mandrel and can be gradually wound and stacked on the mandrel. The mandrel moves in horizontal direction and rotates. This enables production of tubular structures with a unidirectional non-crimp reinforcement structure.
To produce a full layer of reinforcement structure covering the whole mandrel surface, the mandrel has to be moved through the machinery only once. This leads to a very short manufacturing time for every single layer and an overall high preforming productivity.
The local availability of this new machine type at ITA will allow interested European industry partners to benchmark, prototype and validate their potential composite products with a real non-crimp reinforced fibre structure.
A video sequence showing the machinery and its working principle can be viewed at the ITA stand. In addition a demonstrator will be displayed.
1. Car roof segment based on integral reinforced fabrics
The car roof segment was completely produced for the first time out of integral reinforced fabrics . The textile architecture according to load paths allows the reduction of component weight by a higher exploitation of the fibre properties.
Production costs will decrease through less waste and process steps during preforming because the single integral reinforced layers are manufactures in a single step by open reed weaving. For further information please contact firstname.lastname@example.org.
2. Textile-reinforced concrete table
The table made out of textile-reinforced concrete (TRC) visualises the enormous future potential of this innovative composite material.
This potential is based on the high load bearing capacity of textile-reinforced concrete components as well as their resistance to corrosion compared to conventional reinforced concrete. The flexible textile reinforcement allows the production of thin, individually shaped and light concrete structures, which offer outstanding mechanical characteristics and durability. The conception for this textile-reinforced concrete table is based on a quadraxial carbon fibre fabric, which is coated with epoxy resin. As a result the tabletop has almost isotropic properties which allows a thickness of only 15 mm.
The potential target groups are manufacturing companies specialised on textile- or concrete products as well as construction companies. Those companies will be able to extend and diversify their range of products due to the increased possibilities of design and application of textile-reinforced concrete components. Moreover those components represent an interesting alternative to private users and small construction companies because they are applicable with less machine expenditure than conventional reinforced concrete and can be applied in new areas which were not suitable for concrete until now.
3. 3D-woven omega stringer
The 3D-woven omega stringer is made out of 12 k carbon fibre-roving produced on a conventional narrow weaving machine. A cost and time reduction is possible compared to conventional prepreg and multi layer laminate. Due to a near-net shape production there will be little to no scrap. The production technique is suitable for conventional narrow weaving looms; hence there is no need for specialised machines.
The 3D-woven omega stringer is an example for the direct profile weaving based on a typical reinforcement profile as it is used e.g. for reinforcing the pressure bulkhead of an airplane
Target groups for this technology are the aerospace and automotive industry.
ITA demonstrates with this know-how its expertise in an automated near net shaped production of 3D reinforcement profiles e.g. I-, T- and Omega-Profiles with an established process on conventional narrow weaving looms. The technology is immediately available.
3. Demonstration of the process chain precursor production – composite structure „From the fibre to the component“
ITA demonstrates at JEC 2016 the inhouse process chain for carbon fibre production.
It can determine influencing factors on the mechanical properties (e.g. fibre – matrix adhesion). This might be interesting for the target group manufacturers of precursor or carbon fibre. The carbon fibre production process has already been tested by ITA. ITA can manage to produce carbon fibre custom-made.
ITA‘s part in carbon fibre fabrication consists of testing the new precursor materials and of optimising the carbon fibre production and energy efficiency.
4. Folded Textile Reinforced Concrete Element
The folded textile reinforced concrete element enables new design possibilities for TRC facade elements. A new folding tool realises the folded TRC-structure. The folding process is performed during the green stage of the concrete matrix. The process allows folded and curved geometries for ventilated façade panels.
The target group comprises textile manufacturer, TRC producers and architects. The new developed tool enables a small scale serial production (50-100 elements). ITA develops the textile reinforcement for the TRC-folded elements. This includes locally adapted biaxial warp knitted fabrics with a specially designed bending behavior. Marketing is planned to start at the end of 2016.
5. Braided profile made out of thermoplastic fibre reinforced plastic with integrated inserts
The profile was manufactured by overbraiding a mandrel with a hybrid yarn.
ITA determines with this exhibit its expertise in the area of braiding pultrusion. The inserts are directly over braided. There is no need for processing after consolidation. Therefore no fibre cutting is necessary. Further advantages are short production times, high production efficiency and less process steps. This technology is of high interest for the branches automotive and aerospace industry and ready for the market prospectively in 2017 to 2020.
6. Laser drilled preform with integrated insert
This demonstrator shows the highly precise laser processing of carbon fibre preforms for the integration of tailored fasteners or inserts.
It exhibits the potential of laser processing of carbon fibre preforms for composites. Process steps and times can be reduced by using this laser technology. With this method ITA determines its expertise in preforming and insert integration.
7. Locally reinforced fabric with integrated insert
The reinforcement of the locally reinforced fabric with integrated insert can be installed directly during the fabric production
The reinforcement design proceeds in accordance to the load paths. Further advantages are a weight-optimised part scheme and a reduced number of preforming steps and waste. ITA moulds the reinforcement design and conducts the testing.
8. Radial braided basaltic fibre structure
The radial braided basaltic fibre structure withstands temperatures exceeding 800 °C. It has a density less below 3 g/cm³. These properties offer a wide range of applications due to higher robustness even at high temperatures e.g. in turbine and engine development
ITA determines its expertise in braiding of the preform.
Lightweight construction for aeronautics and transport including sustainability
High performance carbon fibre reinforced plastics (CFRP) have firmly established themselves in modern airplanes. Repairs, however, are very laborious and often even impossible. Most of the time the entire component has to be replaced. The PYCO Research Division at the Fraunhofer Institute for Applied Polymer Research IAP in Potsdam, Germany, has developed a simple, cost-effective and energy-efficient way to make sustainable repairs. Moreover, entire components can be completely recycled in a process in which the expensive carbon fibres are reclaimed. Researchers will present their developments at JEC World in Hall 5a, Booth D52
Composites made from crosslinked polymers – so-called thermosets – are reinforced with carbon, glass or natural fibres. Their rich spectrum of properties have increased their importance in aerospace, the automotive industry, wind power generation, shipbuilding, railway construction, building construction, and civil engineering. Yet, even the best material can become damaged or show wear and tear. Engineers must then decide whether the defective area should be painstakingly and expensively patched, or whether the entire component has to be replaced.
“Repairing and recycling polymer-based composites are inseparably linked to resource efficiency and sustainability”, explains Dr Christian Dreyer, who leads the Research Division Polymeric Materials and Composites PYCO at the Fraunhofer IAP. “Finite resources increase the importance of sustainable management and the use of recyclable and repairable polymer materials”, says Dreyer.
The researchers have therefore developed a process for repairing and chemically recycling fibre-reinforced thermosets. These are especially used as matrix resins in composites for high-stress components. The crosslinked polymers form a very rigid structure that gives the component its shape. But it is precisely this structure that creates a problem when it comes to repairing or recycling the component. Unlike thermoplastics, once thermosets are cured, it is very difficult to chemically decompose them.
Repairing and reclaiming – simple, cost-effective and energy-efficient
“We have developed a fast and gentle way for a chemical recycling. It allows highly crosslinked plastics to be broken down into their basic elements”, Dreyer explains. This development enables a component to be completely recycled or to be repaired locally. The resin matrix is gently removed from the defective area without significantly impacting the mechanical properties of the reinforcement fibre. The exposed fibres are then refilled with repair resin and cured.
The new process is also setting the standard for recycling. Until now, discarded components have been either incinerated or shredded to be used as fillers. The Fraunhofer researchers have the crucial advantage when it comes to chemical recycling: the often expensive reinforcement fibres are reclaimed alongside the decomposed polymer matrix. Due to the limited size of the components, the fibres are no longer continuous filaments. Nevertheless, there are many applications using fibres measuring up to several centimetres.
Professor Alexander Böker, who heads up the Fraunhofer IAP explains: “This recycling process is of particular interest to companies since the matrix material can also be recycled on an industrial scale. This allows sufficient quantities of new ‘recycling thermosets’ to be synthesized. The Fraunhofer Pilot Plant Centre for Polymer Synthesis and Processing PAZ – a joint in