New powder gel coat for RTM process

Transcription

1 New powder gel coat for RTM process High productivity manufacturing process of composite parts based on zero emissions fast curing coatings and heated moulds ECOGEL CRONOS 1

2 PROJECT Main Objective To develop an innovative and high productivity Resin transfer Moulding (RTM) process by means of the use of i) fast curing zero VOCs emissions powder gel coats and ii) 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. POWDER GEL COAT WITH & WITHOUT CONDUCTIVE PROPERTIES 2

3 New powder gel coat: objectives & problem targeted Use of innovative powder gel coat in RTM production is only possible if new moulding technologies are developed: Introduction of replaceable/reusable electrically conductive temperature controlled skin prepared off line Release agent, gel coat & fibre: applied to the skin, whilst other is being injected. The established target values for powder gel coat developments are: Peak Cure Temperature: ºC Gel time: seconds (at 120ºC) Storage stability (based on Tg, it has to be => 40ºC and Stability test; introduction of samples in and oven at 35ºC during 7 days. Agglomeration formation and handedness) Additionally, for conductive powder gel coat; resistivity of Ω cm, or lower values, are considered suitable for e-coating. 3

4 1. Application of powder gel coat onto conductive heated skin. ECOGEL proposed RTM process 2. Powder gel coat cured in conductive heated skin. Forming a film. 5. Component and conductive heated skin removed from mould, (post cure cycle starts). 3. Chosen reinforcement added. 4. Resin injected into RTM mould.

5 New powder gel coat: objectives & problem targeted 5

6 AIMPLAS IN ECOGEL CRONOS AIMPLAS is a Centre for Innovation and Technology (CIT) Focus: materials, processes and plastic products and composites. AIMPLAS is member of REDIT and FEDIT, and is involved in SUSCOMPNET, EUROVIPP, EuCIA, AESICOM and IBEROCIT. Around 120 employees: Phd 11%, Graduates & Engineers (5+ year degree) 43%, Graduates & Engineers (3 year degree) 15%, Completed formal education & Technical training 28% and Others 3%. Working areas Technical services: Laboratories (Chemical, Physical-Mechanical, Packaging, Automotive, Construction), Processing Pilot Plants (thermoplastics, thermosets and composite materials). Technical Information: Specialized Technological Watch System (TWS) for the Plastic Industry Training: University Specialist Degrees from Polytechnic University of Valencia, Specialised courses, Training programmes for the plastic sector, Organization of technical conferences and sectorial seminars. R&D: NATIONAL (More than 90 on-going projects in 2010) & INTERNATIONAL (More than 50 Projects finished or ongoing since 2000, 16 of them coordinated) Main topics: - Development and improvement of polymeric materials - Improvement of plastic processing - New product development 6

7 AIMPLAS IN ECOGEL CRONOS THERMOPLASTIC PILOT PLANT THERMOSETING PILOT PLANT LABORATORIES TRAINING ADMINISTRATION TECHNICAL INFORMATION & R & D MANAGEMENT Total f current facilities: 5000 m² Analysis & testing laboratories Pilot plants 7

8 WP2 Objective: New powder gel coat development RTM process Study and development of powder gel coat formulations and its adaptability to the RTM production environment foreseen. Task 2.1 Registry of powder gel coat formulations and suitable ingredients LEADER ECOINNOVA Task 2.2 Modification on chemistry and curing kinetics of powder gel coats LEADER MEGARA Task 2.3 Development of electrically conductive powder gel coats LEADER AIMPLAS Task 2.4 Adaptation of modified formulas to the RTM production LEADER SBS 8

9 Accomplishments and key results - Unsaturated Polystyrene (UP) powder resin development and synthesis UP with Tg > 55 ºC. Curing package selection (inhibitor and initiator) Powder gel coat ingredients selection - Higher application yield (grams/m 2 ) - Class A surface appearance / Film levelling - Lower shrinkage - Surface hardness / Mechanical properties - UV radiation stability / Outdoor resistance - Mould-flow / Secure and consistent compounding extrusion process 9

10 Accomplishments and key results Non-conductive powder gel coat -Powder gel coat samples were obtained by compounding the starting formulations for DSC evaluation and measurement. -Extrusion screw configuration and process parameters already determined. -Some samples showed good gel time value, storage stability and overall reactivity according to ECOGEL CRONOS objectives. -Afterwards, properties and curing kinetics of powder gel-coat were optimized according to ECOGEL CRONOS requirements. SBS extruder 10

11 Accomplishments and key results Conductive powder gel coat Objective: Compounded a powder gel coat doped with fillers which endows the part surface with sufficient electrical conductivity to ensure the electrostatic coating process (E-coating). The processing protocol has been proven. -Twin screw extruder configuration and feeding port position for base formulation. -Surface electrical conductivity was measured Different extrusion trials with different conductive fillers were completed. 1 formulation for powder gel coat with electrically conductive properties was selected AIMPLAS Extrusion line and calendar for Ecogel Project. Measurement of surface electrical conductivity 11

12 Accomplishments and key results Adaptability of successful sample formulations to the RTM real production environment: -Powder particle size distribution -Powder Spray parameters -Powder gel coat Quality control plan Demo parts requirements and testing procedures identified. POWDER GEL COAT QUALITY CONTROL PLAN - Edition 1 February 2015 CHARACTERISTIC TOLERANCE RANGE TEST STANDARD Gel Time 120ºC seconds ISO Max. Peak Temperature (ºC) 140ºC - 146ºC Particle Size over 10μ > 95% ISO Particle Size over 75μ 17% - 21% ISO Particle Size over 120μ < 2,5% ISO Particle Size D μ ISO Colour Difference (ΔE CMC) < 0,6 BS 6923 Visual colour Difference According to DAF colour master 12

13 Accomplishments and key results Electrically heated pilot plant mould A pilot plant mould is available to be used to: determine the range of temperature related to powder gel coat thickness. manufacturing laminates to test powder gel coat adhesion. 13

14 Accomplishments and key results Powder gel coat curing parameters in a RTM production scenario at pilot plant level. First trials completed with electrically heated pilot plant mould to evaluate heating homogeneity and heating rate. To compare signals from the temperature sensors and actual temperatures. First trials completed with powder paints. Safe Powder Coating Guideline (from CEPE, European Council of Paint, Printing Ink and Artist) reviewed and taken into account to complete the design of experiments planned. 18th month meeting 26th February Brussels 14

15 NEXT STAGES Powder gel coat curing parameters in a RTM production scenario at pilot plant level 15

16 Conclusions up-to-date Powder gel coat topcoat formulation (non-conductive properties) is ready to start with pilot plant applications and cured film testing stages for the final formulation adjustment (preliminary DAF and BENTLEY requirements). Results obtained with the conductive powder gel coat preliminary trials have also shown several formulations fulfilling ECOGEL CRONOS process requirements as well as surface conductivity targets. One formulation was selected for next trials at pilot plant application. Next pilot plant application trials will determine which of the candidate formulations has to be produced for scale up trials and, therefore, lab testing according to BENTLEY and DAF demo part technical specifications. 16

17 Never innovate to compete, innovate to change the rules of the game. David O. Adeife 17

18 Anabel Crespo Raquel Giner Borrull This project has received funding from the European Union s Seventh Framework Programme for research, technological development and demonstration under grant agreement no

19 AIMPLAS and the new powder gel coat EXPECTATIONS. Know-how about fast curing RTM process using power gel-coat. Transfer the knowledge gained in ECOGEL to other sectors. Increase our contacts between companies and research centers at European level. Exploitation interest: New conductive powder gel-coats for other industries (mainly transport application). WP2. Development of powder gel coat for RTM process. WP2 Objective: Study and development of powder gel coat formulations and its adaptability to the RTM production environment foreseen. 19