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ECOGEL–CRONOS: High productivity manufacturing process of composite parts based on zero emissions fast curing coatings and heated moulds.
Anabel [email protected]
Conecte con @aimplas
Contents AIMPLAS introductionECOGEL-CRONOS project
◦ The need for weight reduction◦ Project Overview◦ Resin Transfer Moulding Process◦ Powder gel coat: main advantages.◦ Electrically heated skins technology.
Conclusions
MARCH 2015
Index
o 01. AIMPLAS introductiono 02. Key drivers of innovation in the automotive industryo 03. European CO2 regulations in vehicleso 04. Innovations
Composites from anionic polyamides Composites from carbon fibres Composites from natural fibres
o 05. Conclusions
AIMPLAS Introduction
AIMPLAS is a Technology Centre with more than 25 years of experience helping companies in the plastic sector.
Over 8,500 m2 facilities with state-of-the-art equipmentand instrumentation.
+530
members
+1,500
customers
€ 8.6M
revenues
2014 DATA
What is AIMPLAS?
Revenues byactivity
RGB20/5/95
MEMBER COMPANY FEESOTHERSTECHNICAL INFORMATION
TRAINING
SERVICES & TECHNICAL
ASSISTANCE R&D&InnovationPROJECTS
Mar
keto
rient
ed
RGB20/5/95Global expertise across the whole plastics value chain
Production and/or distribution
of plastic raw materials
Production and/or commercialization of semi-manufactured
raw materials “COMPOUNDING”
Manufacturing / Processing End users Recovery
of plastic waste
What is AIMPLAS?
> R&D&Innovation Projects
> Analysis and Testing
> Material Processing
> Technical Assistance
> Competitive Intelligence
> Training
Solutions for Plastics
R&D Lines
Development of polymeric materials
Improving transformation processes
Product development
123
Index
o 01. AIMPLAS introductiono 02. Key drivers of innovation in the automotive industryo 03. European CO2 regulations in vehicleso 04. Innovations
Composites from anionic polyamides Composites from carbon fibres Composites from natural fibres
o 05. Conclusions
ECOGEL-CRONOS project
The need for weight reduction
INNOVATION KEY DRIVERSEU Regulations
Weight reduction
FUEL efficiency
Emissionsreduction
Innovation key drivers
The need for weight reduction
New Car CO2 emissions
Challenge:
To achieve a vehicle weight reductionof 12% by 2020 (25% by 2030) to meet the EU CO2 emissions targets.
The need for weight reduction
Business opportunity:
To implement technologies and design solutions to delivervehicle weight savings that are market ready for 2020 and do not incur a cost penalty.
the weight down spiral
The need for weight reduction
Innovation keydrivers
EU RegulationsWeight reduction
FUEL efficiency
Emissionsreduction
COMPOSITES
Cost Reduction
Short Cycle Times (<60 s.)
The need for weight reduction
DIFFERENT STRATEGIES •Development of partnerships with carbonmanufacturers to create carbon fibre supplychain designed exclusively for vehicles(reduction of carbon fibre price) • Cooperative agreements with resinmanufacturers to reduce the curing time of resins Snap-cure resins• Agreements with equipment manufacturersfor process optimization HP-RTM• Introduction of thermoplastic resins In-situ polimerization process.
Comparison between Carbon fibre/matrix bond strength[1].
[1] Literature – CF/thermoplastic composite interface bond:Composites Part A 28A (1997) 587-594 – 4.3 to 6.8ksi IM7-TP2005 SPE Automotive Composites Conference & Exposition, Troy, Mich., USA. 4.7 to 8.1ksi, PA6-AS4.COMPOSITES 2006 October 18-20, 2006, 6.7 to 7.1ksi,PA6-carbon fiber.
16
Project overview
ECOGEL-CRONOS. Grant agreement nº 609203 High productivity manufacturing
process of composite parts based on zero emissions fastcuring coatings and heated moulds
Theme FoF. NMP.2013-10. Manufacturing processes for productsmade of composites or engineered metallic materials.
Funding scheme: Collaborative Project
Duration 36 months. Starting/ending: 1st Sep 2013 / 31st Aug2016
17
Project overviewOBJECTIVES:
To develop an innovative and high productivity Resin transfer Moulding(RTM) process by means of the use ofi) fast curing “zero VOCs emissions” powder gel coats andii) electrically conductive hot skin mould technologies based on
laminates made of carbon-fiber- plastics (CFP laminates)to mass production parts for automotive and goods transport sector.
18
Project overview
OBJECTIVE:
To develop an innovative and high productivity Resin transfer Moulding(RTM) process by means of the use ofi) fast curing “zero VOCs emissions” powder gel coats andii) electrically conductive hot skin mould technologies based on
laminates made of carbon-fiber- plastics (CFP laminates)
to mass production parts for automotive and goods transport sector.
Materials for composites parts.Materials for mould construction.Modelling.Moulds design and construction.Case studies.
Project overview
Cost reduction
Improved design Materials improvement Reduced secondary
processes
cost down potential
Materials cost reduction
Secondary process reduction
Powder gel coat: main advantages.OBJECTIVES
• Two different formulations:• Non-conductive powder gel coat final finishing of the
parts.• Conductive powder gel coat primer for electrostatic
painting.
ECOGEL target values for powder gel coat developments:• Peak Cure Temperature: 110-130 ºC• Gel time: 20-60 seconds (at 120ºC)• Storage stability (based on Tg ≥ 40ºC)• Electrical conductivity: resistivity ≤ 10+5 Ω cm
Powder gel coat: main advantages.
• Final results in comparison with liquid powder gel coat
Non-conductive powder gel coat
Test Liquid gel coat Powder gel coatVOC emissions -Chemical resistance +++ ++Cross-cut tests +++ +++UV resistance ++ +++Curing time 20 min 3 min
85% time reduction!
- needs to be improved + good ++ very good +++ excellent
Powder gel coat: main advantages.
• Final results in comparison with liquid powder gel coat
Conductive powder gel coat
Test Liquid gel coat
Powder gel coat
Primer(secondary
process)VOC emissions - -Cross-cut tests +++ +++ ++
Resistivity n.a. ≤ 10+5 Ω cm ≤ 10+5 Ω cmCuring time 20 min 10 min
50% time reduction!
Cost and time
reduction!!- needs to be improved + good ++ very good +++ excellent
Electrically heated skins technology
The technology to heat up the powder Gel Coat is one of the key elements to improve the productivity in the Ecogel Cronos-project.
Carbon fibre as resistivity element
Index
o 01. AIMPLAS introductiono 02. Key drivers of innovation in the automotive industryo 03. European CO2 regulations in vehicleso 04. Innovations
Composites from anionic polyamides Composites from carbon fibres Composites from natural fibres
o 05. Conclusions
Conclusions
Conclusions
Trends on RTM Technology Progress
Dramatic reduction of cycle times. Ideally < 5 min to compete with SMC production volumes Fast
Higher number of parts. Typically > 25.000 parts per annum Fast
Introduction of various types of reinforcements to replace fibre glass Medium
Use of fibre preforms to reduce fibre lay-up time Medium
Introduction of fast curing resin formulations (epoxy, polyester, PU) Medium
High pressure injection vacuum aided Fast
Improved tooling with efficient heating capabilities and insert skins Fast
Expansion to the automotive market through automation Fast
Improvement of part finish for secondary operations (painting, bonding) Fast
ConclusionsSUMMARY of ECOGEL Project MAIN ACHIEVEMENTS to data.
Selection of the case studies and definition of the project baseline.
Selection of powder gel coat final formulations : with and without conductive properties (black and white coloured, respectively). Simulations programs were employed to determine conductivity threshold.
Modification of epoxy, vinylester and urethane acrylate injection resins to enhance compatibility between them and the powder gel coat developed.
Selection of high Tg resin and gel coat for electrically heated skin manufacturing: extensive tests performed and optimized.
Prototype mould and skin designed, thermo-mechanical simulations accomplished and manufacting and testing phased finished - currently working on the manufacturing of moulds and skins for the demonstrators.
ConclusionsSUMMARY of ECOGEL Project MAIN ACHIEVEMENTS to data.
Binder selection based on mechanical characterization tests, simulations and permeability tests finished. Preforms for the prototype mould finished and tested. Currently, working on preforms for demonstrators.
New range of adhesives based on the chemical combination of epoxy and urethane groups has been developed and are being tested.
First economic approach finished, but still more actual data is needed for the whole process to get a more accuracy assessment.
First part of the LCA finished.
Conclusions
SUMMARY of ECOGEL Project MAIN ACHIEVEMENTS related toPOWDER GEL COAT.
Reduction of gel coat application time in 85% for final finishing of the parts.
Important reduction on secondary processes when using conductive powder gel coat (removing primer application for electrostatic painting in automotive sector) important reduction in labour cost.
Reducing VOC emissions due to gel coat application in the workplace energy savings due to reduced need for ventilation and fulfil EHS (environment, health and safety) requirements, reduction of waste, smaller premises for production and storage, etc.
Improving UV resistance for final finishing parts.
Thank you foryour attention
Contacte con nosotros:[email protected]. 96 136 60 40
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