UV-LED CURING OF LIGHTWEIGHT MATERIALS

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1 UV-LED CURING OF LIGHTWEIGHT MATERIALS RadTech Europe Conference October 2017, Prague, Czech Republic Dr. Christian Dreyer Research Division Polymeric Materials and Composites PYCO Fraunhofer

Fraunhofer IAP at a Glance 220 employees, incl. PhD students, apprentices, etc. ca. 20.

2 Fraunhofer IAP at a Glance 220 employees, incl. PhD students, apprentices, etc. ca million institute s budget ca million external revenues research sites: Potsdam-Golm Schkopau Schwarzheide Teltow Wildau 2

(PLA, PHA, PA), fibers, blends and composites Functional Polymer Systems Dr.

OLEDs, polymer electronic components, organic solar cells Synthesis and Polymer

Thorsten Pretsch polymer synthesis and process development,

shape-memory polymers Pilot Plant Center PAZ Prof. Dr.-Ing.

3 Research Divisions Biopolymers Dr. Johannes Ganster biopolymers (cellulose, starch, lignin), biobased plastics (PLA, PHA, PA), fibers, blends and composites Functional Polymer Systems Dr. Armin Wedel materials with specific optical and electronic properties, polymeric OLEDs, polymer electronic components, organic solar cells Synthesis and Polymer Technology Dr. Thorsten Pretsch polymer synthesis and process development, microencapsulation/particle applications, function integrated polymer films, shape-memory polymers Pilot Plant Center PAZ Prof. Dr.-Ing. Michael Bartke polymer synthesis and processing, scale up to ton scale Life Science and Bioprocesses Prof. Dr. Alexander Böker keratin fibers, biotechnological processes, protein conjugates, self-assembly techniques, smart materials for medical applications Polymeric Materials and Composites PYCO Dr. Christian Dreyer thermosetting resins for applications in lightweight construction and micro- and optoelect 3

4 Zwanzig20 Funding Program T e ty20 Part ership for I ovatio (German: Zwanzig 20 Partnerschaft für Innovation) Funding program of the German Federal Ministry of Education and Research targets international, inter-, trans- and multidisciplinary partner collaboration and stands for openness and transparency 500 million funding in total 45 million for every consortium from 2014 until 2020) Development of outstanding economic and scientific competences established in East Germany for the future through national and interdisciplinary collaboration T e ty20 consortia are regarded as open and transparent partnerships and are therefore also open to new collaboration partners in the implementation phases Further information: 4

5 Advanced UV for Life Consortium 5

6 Zwanzig20 Consortium Advanced UV for Life - AUVL Alliance of 24 enterprises and 13 research institutes with focus on development and use of UV-LEDs Goal: To promote technical development, availability and application of UV-LEDs on a large scale Subsitition of the (dominant) Hg-based UV-sources Opening up new areas of application Development of UV-LED-based components, systems and process technologies along the complete value chain 6

7 Zwanzig20 Consortium Advanced UV for Life - AUVL Total funding: 45 Mio. 7

8 Basisvorhaben Systematic research on development and curing of resins using UV-LED Modules Inno-UV-Faser Development and characteri-zation of UVcurable glass-fibre coatings with low refractive index UV-Co-Light Development of UV-curable resins for pultrusion and large area glass-fibre components UV-Endlos Material- and processoptimization for continuous materials in lightweight construction OUD-LED Further development and optimization of inkjetable UV- LED curable Photo-polymers für digital printing planned e.g. UV-LED based 3D-Printing Projects of Fraunhofer IAP-PYCO within AUVL 8

9 Basisvorhaben Systematic research on development and curing of resins using UV-LED Modules Inno-UV-Faser Development and characteri-zation of UVcurable glass-fibre coatings with low refractive index UV-Co-Light Development of UV-curable resins for pultrusion and large area glass-fibre components UV-Endlos Material- and processoptimization for continuous materials in lightweight construction OUD-LED Further development and optimization of inkjetable UV- LED curable Photo-polymers für digital printing planned e.g. UV-LED based 3D-Printing Projects of Fraunhofer IAP-PYCO within AUVL - Lightweight Material Related 9

10 UV-LED Modules used for the AUVL-Projects (selection) 10

11 UV-curing of Glass-Fibre Reinforced Materials - Fundamentals 11

m x 30 m) GFRP panels Formulation of new UP-

12 UV-Co-Light: Production of Glass-Fibre Reinforced Polymers Development of UV-curable, flame retardant resin formultions for pultrusion profiles and large scale (3,3 m x 30 m) GFRP panels Formulation of new UP- and VE-resins Use of UV-LED modules and Hg-lamp substitution 12

13 UV-Co-Light: Thermosets for Lightweight Components Development of UV-curable flame-retardant thermosetting resins for pultrusion profiles and large scale GFRP-panels Formulation of new UP- and VE-resins Use of UV-LED Modules and substitution of the mercury-lamps by the industrial partners Resin Photoinitiator Wavelength Curing Speed [mm/s] Max. curing deepness [mm] Conversion in 10 mm deepness [-] Conversion at the Surface UP 1 IGC nm ,95 0,93 UP 1 IGC nm ,97 0,95 UP 1 IGC nm ,96 0,87 UP 1 IGC nm ,59 0,55 VE IGC nm 5 - No curing VE IGC nm ,39 0,94 VE IGC nm ,52 0,67 VE IGC nm ,88 0,67 [-] 13

Remark UV 9300 UV 9315 UV 9700 UV 9390 C UV 9390 C UV 9390 C Low to medium release properties Low release

14 UV-Endlos: Thermosets for Continuous Processes Development of coating resins for release papers Curing with UV-LEDs at different wavelengths Determination optimium combination of resin and wavelengths Resin PI Remark UV 9300 UV 9315 UV 9700 UV 9390 C UV 9390 C UV 9390 C Low to medium release properties Low release properties fast and complete curing High viscous Epoxy-resin for open substrates and Applications with bitumen 14

15 Sandwich Structures Photo: PYCO t 2 t 4 t Relative bending stiffness 1 7,0 37 Relative bending strength 1 3,5 9,2 Relative weight Foto: PYCO 1 1,03 1,06 15

16 Core-Materials (Selection) Foam and Balsawood ################# Aluminium- and Nomex-Honeycombs PVC-Honeycombs Source: Husumwind Veneer-Core Source: CTM Polycyanurate Foam Source: Quingdao Hexcore Composites Spacer Fabric Source: Schotten und Hansen Tubus-Core Source: PYCO Balsawood Source: PYCO Fold-Core Source: Tubus-Waben GmbH Source: Global Shop Source: PYCO 16

17 Alternative Core Materials Nap-Core Broad Application spectra by variation of fabric and/or resin Good cylindrical and semi-spherical drapability Drainability due to open structure Easy integration of cables and wires Good noise damping High flame retardancy possible Low density ( kg/m³) 17

18 Alternative Core Materials Nap-Core 18

modules with different wavelengths Type Material STS 004 95% Cellulose, 5%

19 UV-Endlos: Continuous Production of Alternative Core Materials (Nap-Core) Currently use of standard unsaturated polyester resins Curing with UV-LED modules with different wavelengths Type Material STS % Cellulose, 5% Elastane M&A % Polyester NHS 86% Nomex, 9% Polyamide, 5% Elastane % Glass 19

20 UV-Endlos: Continuous Production of Alternative Core Materials (Nap-Core) Selection of non-woven fabrics used for UV-cured nap-cores Material Weight per area 100% Glass 400 g/m² 100% PES 95 g/m² 100% PyroTex 90 g/m² 80% Aramide, 20% Polyester 86 g/m² 95% Cellulose, 5% Elastane 245 g/m² 95% Polyester, 5% Elastane 190 g/m² 100% Polyester 260 g/m² 86% Nomex, 9% Polyamide, 5% Elastane 200 g/m² 100% Glass 360 g/m² 20

21 UV-Endlos: Continuous Production of Alternative Core Materials (Nap-Core) Selection of UV-cured nap-cores Photographs courtesy of InnoMat GmbH 21

22 Thank you very much for your attention! Questions? Fraunhofer-Institute for Applied Polymer Research IAP Research Division Polymeric Materials and Composites PYCO Dr. rer. nat. Christian Dreyer Acting Division Director Kantstraße 55, Teltow, Germany Phone:

Security Inks for Textile Applications and other Research Topics of DITF

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