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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

Project overview

Resin Transfer Moulding Process

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.Non-conductive powder gel coat

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

Powder gel coat: main advantages.Conductive powder gel coat

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

Electrically heated skins technology

Electrically heated skins technology

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

www.facebook.com/aimplasTwitter: @aimplas


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