Low Cost Hook-and-Loop 3D Composites Enable Automatic Laying-Up Fabrics for Mass Production Preforming

Transcription

1 Low Cost Hook-and-Loop 3D Composites Enable Automatic Laying-Up Fabrics for Mass Production Preforming Nathan Nanlin Han, Ph.D. 3D Nanocomposites, Inc. Valencia, CA, USA At SPE ACCE Han-3D Composites

2 Contents Introducing 3D hook and loop composites New-3D-Composites increase mechanical strength Hook and loop grippers of Han-layup-robot Automation of preforming Han-3D-composite parts made by high pressure RTM

3 3D Concrete,2D Composite 3D Concrete 2D Composite Pictures cited from Internet

4 2D and 3D Composites Stitch 3D, High cost 2D Lay Up, Low cost 3D Weaving, High cost 90%-95% Market Share 5%-10% Marked Share 3D Braid, High cost Pictures cited here from Internet

5 Low Cost 3D Hook-and-Loop Fabric Solution Velcro 3D Lay Up, Low cost Velcro 3D Lay Up, Low cost Fiberglass Han-3D-Fabrics

6 3D Hook-and-Loop Fabrics Named as Han-3D-Fabrics Carbon Fabrics, Aramid Loops Carbon and Fiberglass Fabrics Aramid Fabrics Fiberglass Fabrics

7 Hook-and-Loop Fabrics Get 3D Composites Hook-and-Loop Fabrics 3D Composite Hook-and-Loop Fabrics is similar to plain weave fabrics. It is about 30%-40% more in cost. However automation can reduce whole cost of production.

8 Increase Mechanical Properties Tear strength increase % Bend strength increase 5-10% Shear strength increase15% Hook and loop fabric has the same tensile strength as plain weave fabrics.

9 Tensile Strength Samples L (mm) B (mm) D (mm) F (N) Strength (MPa) Strength (MPa) HL HL HL HL PW PW PW PW HL=Hook and Loop, PW=Plain Weave

10 The Difference in Tensile Curve Hook and Loop Plain Weave Hook and loop effect: strength increases just before failure

11 Shear Strength Shear load: N Average Increase HL PL % Pull

12 Impact Strength Increase about 100% Hook-and-Loop Regular 2D Regular 2D Impact loads reduce 50% to get similar dent size.

13 Won 2010 JEC Paris Innovation Award

14 Composite Application Fields, How Much by Automation? Composite market is 68 Billion Euro in 2010 according to JEC. How much composite products are made by automation process? Pictures cited from Internet

15 Resin Transfer Molding Process Three major processes RTM,RFI and Injection Molding will integrate to increase efficiency and reduce cost for composites. Picture cited from Internet

16 RTM Process Major Two Parts: Preforming and Curing Han-3D-Fabrics and Han-Layup Robots enable automations. Picture cited from Dieffenbacher.

17 Hand Lay-up Fabrics Hand lay-up fabric process is too slow and too expensive for a mass production. Pictures cited here from Internet

18 Hand Lay-up, Extensive Labor Work 2D lay up Pictures cited from Internet

19 Hook and Loop Grippers Enable Automation Laying-up Picture cited from Umeco, Dieffenbacher.

20 Gripping Mechanism is Critical for a Layup Robot Picture cited from Dieffenbacher.

21 Hook-and-Loop Gripper for a Han-Layup-Robot Gripper Fabric Pick up Fabric Release Fabric Hook and Loop Gripper Enables Automation of Laying-Up Fabrics.

22 Han-Layup-Robot Gripper Picks up and Releases Fabrics Pick up Fabric Release Fabric International Patents Pending Han-Layup-Robot Enables Automation of Laying-Up Fabrics.

23 3D Composite Car Body Model 3D Structure, Stronger, Lighter, Lower Cost

24 Hook and Loop 3D Composite Parts Made by High Pressure RTM Han-3D-Composite Parts Made by High Pressure RTM at KraussMaffei Germany.

25 3D Nanocomposites, Inc. is building Car Body with 3D Composites for Formula Student Pictures cited from Internet

26 Mass Production Composite Car Body Needs Breakthroughs Four major breakthroughs enough support mass production of composite car body to come real. 1. Hook-and-loop Composites/Han-3D-Composites 2. Automatic preforming by Layup robots 3. Fast curing resin 4. Fast resin infusion technologies for RTM

27 Conclusions Hand lay-up fabric process is a major barrier for applying fiber-reinforced composites in automobile major structures. Now the barrier is removed. Like the new generation of airplane Boeing 787 and Airbus 350, vehicles will take several generations to complete the adaptation of composite bodies. It is estimated that: within 15 years, more than 50% new models will adapt to light weight composite bodies!

28 3D Nanocomposites, Inc. Provides Laid-up Preforms for Customers

29 Thanks The end Nathan Han 3D Nanocomposites, Inc. Valencia, CA, USA