Technology and experiences in manufacturing highly advanced carbon fiber prepreg. Thomas Kolbusch, Vice president

Transcription

1 Technology and experiences in manufacturing highly advanced carbon fiber prepreg Thomas Kolbusch, Vice president COATEMA Coating Machinery GmbH 1

2 innovations Introduction Coatema quality made in Germany Part of the ATH Holding working widths from100 mm coating Bespoke equipment up to 5,400 mm printing laminating founded 1974 Film/Paper Printed Electronics Prepreg Membranes Renewables Textile Glass From Lab2Fab R&D projects & network worldwide service COATEMA Coating Machinery GmbH 2

3 Group of Companies Foundation 1903 Approx. 200 employees Located in Hamburg Foundation 1995 Approx. 50 employees Located in Norderstedt Foundation 1974 Approx. 45 employees Located in Dormagen Foundation 1919 Approx. 140 employees Located in Hamburg COATEMA Coating Machinery GmbH 3

4 Summary Introduction Coatema Technology background Spreading technology Coating technologies Impregnation technologies Curing / High temperature systems Pilot line layout Proof of concept COATEMA Coating Machinery GmbH 4

5 Introduction Coatema From Lab2Fab Lab Pilot Production Custom made Custom made Custom made Process development Pilot production inline Production line Coatema equipment platform strategy for Lab2Fab COATEMA Coating Machinery GmbH 5

6 Introduction Coatema The one stop shop solution Batch type operation R2R on small scale Semi production on small scale Custom made small scale Pilot production Standard layouts Bespoken equipment on big scale Fab system inline COATEMA Coating Machinery GmbH 6

7 Introduction Coatema Our customers COATEMA Coating Machinery GmbH 7

8 Introduction Coatema Our R&D customers COATEMA Coating Machinery GmbH 8

9 R&D projects overview Flex-G GreenSense ProLiBat FlexEnSys Supersmart COATEMA Coating Machinery GmbH 9

10 The market for prepreg COATEMA Coating Machinery GmbH 10

11 The market for prepreg The market in total Source: AWK composite COATEMA Coating Machinery GmbH 11

12 The market for prepreg The market There are a number of growth markets: Transportation Automotive Sport Aerospace Wind energy Automotive Transportation Medicine Quelle : [BMW, DLR, Coatema, BMW, Carbon Composite, CFK Medical] COATEMA Coating Machinery GmbH 12 Source: BMW

13 The market for prepreg The market in total COATEMA Coating Machinery GmbH 13

14 Technology Background Current turn over in Bill. US$ for different matrix materials (2013) Source: Acmite Market Intelligence e.k COATEMA Coating Machinery GmbH 14

15 Technology Background COATEMA Coating Machinery GmbH 15

16 Prepreg Matrix Fibers Source: Carbon-Deutschland COATEMA Coating Machinery GmbH 16

17 Technology Background Types of material Today there are 3 major composite systems Thermosetting (duroplastic) resins Thermoplastic resins A polymer that cannot be remolten or reformed once it has been cured. Curing creates a molecular cross-linking, which is irreversible. Version B-stage: - Curing stops at incomplete crosslinking - final curing to complete crosslinking after shaping A polymer in which the molecules are not cross-linked, or they are cross-linked to a weaker degree. A thermoplastic polymer can be reshaped or reformed by reheating the polymer. Hybrid systems COATEMA Coating Machinery GmbH 17

18 Technology Background Fibres and substrates Reinforcement Man made fibres Carbon Glass Polyamide (Nylon R) Aramid (Kevlar R) Basalt COATEMA Coating Machinery GmbH 18

19 Technology Background Rovings and textile structure Rovings and textile structure of the substrate Uni- and Bi-directional structures woven substrates Multi-directional fibers construction layer (cross) structures sewed knitted structures Products with more than one orientation direction, this is influenced by the later desired strength direction COATEMA Coating Machinery GmbH 19

20 Technology Background Thermosetting materials Thermosetting (duroplastic) resins solvent or water based epoxy resins phenol systems polyester / vinyl ester / acrylic resin 1K and 2K products (mostly resins) B-stage systems Disadvantages: Ridgid, not meltable, recycling problems COATEMA Coating Machinery GmbH 20

21 Technology Background Specs for thermosetting materials Specs for thermosetting (duroplastic) systems Variation of the coating weight both sides g/m² Range of viscosity (mpas) Temperature range C, standard application temperature C Speed range for different production processes average speed 50-80m/min for film coating process average speed 5-15m/min for combined coating and laminating lines average speed 5-25m/min for impregnation average speed Temperature accuracy ± 1K roller surface temperature and dryer accuracy COATEMA Coating Machinery GmbH 21

22 Technology Background Thermoplastic materials Thermoplastic systems PE Polyethylen PP Polypropylen PC Polycarbonat POM Polyoxymethylen PEEK Polyetheretherketon PA Polyamide PEI Polyetherimid PTFE Polytetrafluorethylen Disadvantages: high viscosities, change of systems for appliance, not finally certified COATEMA Coating Machinery GmbH 22

23 Technology Background Specs for thermoplastic materials Specs for thermoplastic systems powder like materials solvent thermoplastic resins extruded thermoplastic resins Variation of the coating weight 10 to 300 g/m 2 Range of viscosity (mpas) depending on coating or extrusion technology Temperature range C ± 1K Speed range Average speed range for impregnation 0,1-10 m/min COATEMA Coating Machinery GmbH 23

24 Spreading of fibre Coating the resin Impregnation into the matrix Finishing COATEMA Coating Machinery GmbH 24

25 Part 1 - Spreading technologies COATEMA Coating Machinery GmbH 25

26 Spreading of fibre Finishing COATEMA Coating Machinery GmbH 26

27 Technology Background Spreading technology COATEMA Coating Machinery GmbH 27

28 Technology Background Creel station for carbon bobins COATEMA Coating Machinery GmbH 28

29 Technology Background Speading process R μ Friction effect F T Pulling/ traction force R μ F T Source: ITA COATEMA Coating Machinery GmbH 29

30 Spreading technology Speading device Top spreading rods Transfer roller Positioning roller Bottom Spreading rods COATEMA Coating Machinery GmbH 30

31 Technology Background Substrate weight depending on roving fineness and number COATEMA Coating Machinery GmbH 31

32 Technology Background Substrate weight depending on roving fineness and number 12K spreading per roving to 8 mm add up to 100g/m² 12K spreading per roving to 10,7 mm add up to 75g/m² 24K spreading per roving to 8 mm add up to 200g/m² 24K spreading per roving to 10,7 mm add up to 150g/m² 24K spreading per roving to 16 mm add up to 100g/m² COATEMA Coating Machinery GmbH 32

33 Part 2 Coating Technologies COATEMA Coating Machinery GmbH 33

34 Coating the resin Finishing COATEMA Coating Machinery GmbH 34

35 Processes & Technologies Film transfer method Step1: Matrix film coating Step2: Prepreg impregnation Protection film Resin film Protection film Matrix material (Resin) Reinforcement Impregnation Release paper Resin film Resin film Prepreg Source: H. Langsfeld Faserverbundwerckstoffe COATEMA Coating Machinery GmbH 35

36 Processes & Technologies Solvent methods Solvent method Dryer Protektion film Nip rollers Prepreg Reinforcement Matrix bath Protektion film COATEMA Coating Machinery GmbH 36

37 Coating systems Coatema s coating systems Knife Double Side Commabar Case Knife Slot Die Hotmelt Slot Die Engraved Roller Powder Scattering 3 Roller Combi Micro Roller 5 Roller Reverse Roll Double Knife Curtain Coating 2 Roller Combi Dipping Rotary Screen >30 application systems COATEMA Coating Machinery GmbH 37

38 Coating systems Indirect coating Concept: Coating is being done on a carrier film Easy to pre-meter the coating thickness Transport on a support carrier to the next steps High accuracy Reproducibility COATEMA Coating Machinery GmbH 38

39 Coating technologie Indirect coating Modular coating system for prepreg Viscosity (mpas) Temperature range RT 250 C COATEMA Coating Machinery GmbH 39

40 Part 2 - A Thermosetting technology COATEMA Coating Machinery GmbH 40

41 Coating the resin Thermosetting (duroplastic) resins Finishing COATEMA Coating Machinery GmbH 41

42 Coating technologie Indirect coating prepreg line COATEMA Coating Machinery GmbH 42

43 Technology Background Layout for thermosetting production line Creel station Spreading unit Unwinding station COATEMA Coating Machinery GmbH 43

44 Technology Background Layout for thermosetting production line Coating system 1 Hot calender Heating table Coating system 2 ^^ COATEMA Coating Machinery GmbH 44

45 Technology Background Layout for thermosetting production line De-lamination + Lamination station Cutting device Rewinding station Winding-station ^^ COATEMA Coating Machinery GmbH 45

46 Part 2 - A Thermoplastic technology COATEMA Coating Machinery GmbH 46

47 Coating the resin Thermoplastic resins Finishing COATEMA Coating Machinery GmbH 47

48 Production line layouts Thermoplastic process COATEMA Coating Machinery GmbH 48

49 Coating technologie Dipping / Foulard Variation of the impregnation weight Depending on the fabric / UD tape Range of Viscosity (mpas) Temperature range RT 250 C COATEMA Coating Machinery GmbH 49

50 Coating technologies Dipping / Foulard prepreg line Thickness measurement Coating unit Spreading unit Drying rollers unit Calender Cutting device Creel Unwinder for fabric IR-Sintering zone Cooling unit Rewinder COATEMA Coating Machinery GmbH 50

51 Coating technologies Powder Scattering Variation of the coating weight g/m COATEMA Coating Machinery GmbH 51

52 Coating technologies Powder Scattering prepreg line Thickness measurement Spreading unit Coating unit Calender Cutting device Creel Unwinder for fabric IR-Sintering zone Cooling unit Rewinder COATEMA Coating Machinery GmbH 52

53 Coating technologies Hotmelt / Extrusion Variation of the impregnation weight Depending on the fabric / UD tape Range of Viscosity (mpas) Temperature range RT 400 C COATEMA Coating Machinery GmbH 53

54 Coating technologies Extrusion Die / Hotmelt Double Side Extrusion of thermoplastic resins COATEMA Coating Machinery GmbH 54

55 Curing / High temperature systems For the curing / impregnation process of high-tech polymers (PEEK, PEK, PTFE) temperatures from room temperature up to 400 C are needed. Therefor special high temperature roller systems (>300 C) are applied. Direct heated rollers (IR) or Inductive heated roller systems COATEMA Coating Machinery GmbH 55

56 Part 3 Impregantion COATEMA Coating Machinery GmbH 56

57 Impregnation into the matrix Finishing COATEMA Coating Machinery GmbH 57

58 Technologies & Processes Impregnation technologies Resin film Protection film Reinforcement Impregnation Resin film Prepreg COATEMA Coating Machinery GmbH 58

59 Impregnation technologies Impregnation zone COATEMA Coating Machinery GmbH 59

60 Impregnation technologies High precise calender systems with heating table COATEMA Coating Machinery GmbH 60

61 Impregnation / High temperature systems COATEMA Coating Machinery GmbH 61

62 Roll design parameters Geometrical Dimensions - Diameter, Surface width (WOB), Journals Media - Type, flow amount, flow speed, pressure, temperature range Roll material for shell, journals and interiour - Stainless steel, carbon steel, 42CrMo4 with hardened surface Tolerances - true running, cylindricity, surface roughness Surface coating - Chrome, Teflon, Ceramic, Rubber, etc COATEMA Coating Machinery GmbH 62

63 Curing / High temperature systems Direct heated roller (IR) Drilling for PT 100 temperature sensor Rotary feedthrough for electrical connections Source: Wumag texroll Infrared heater Outer shell Screwable shafts COATEMA Coating Machinery GmbH 63

64 Curing / High temperature systems Inductive heated roller systems Source: Tokuden COATEMA Coating Machinery GmbH 64

65 Curing systems Drying with IR technology COATEMA Coating Machinery GmbH 65

66 Production line layouts Thermoplastic process High precise calender systems with IR-sintering dryers COATEMA Coating Machinery GmbH 66

67 Spreading of fibre Coating the resin Impregnation into the matrix Finishing COATEMA Coating Machinery GmbH 67

68 Pilot line layout COATEMA Coating Machinery GmbH 68

69 Click&Coat All line layouts in Click & Coat design Here are a few benefits of the Click & Coat approach: Over 40 coating, printing and ancillary Siemens S7 software solution modules available Fast set up time for new processes or Award winning C&C design for connecting increased through-put and aligning modules Over 40 coating and printing systems for Easy three - wire eletrical connectors plug in and out Patented C&C design for connecting the modules COATEMA Coating Machinery GmbH 69

70 Click&Coat Click & Coat design COATEMA Coating Machinery GmbH 70

71 Click&Coat Click & Coat design COATEMA Coating Machinery GmbH 71

72 Click&Coat for Prepreg Production Cust om COATEMA Coating Machinery GmbH 72

73 Click&Coat for Prepreg Production COATEMA Coating Machinery GmbH 73

74 Click&Coat for Prepreg Production COATEMA Coating Machinery GmbH 74

75 Click&Coat for Prepreg Production COATEMA Coating Machinery GmbH 75

76 Proof of concept COATEMA Coating Machinery GmbH 76

77 Production line layouts Thermoplastic process COATEMA Coating Machinery GmbH 77

78 Production line layouts Proof of concept COATEMA Coating Machinery GmbH 78

79 Production line layouts Proof of concept COATEMA Coating Machinery GmbH 79

80 Production line layouts Proof of concept COATEMA Coating Machinery GmbH 80

81 Production line layouts Proof of concept COATEMA Coating Machinery GmbH 81

82 Thank You COATEMA Coating Machinery GmbH 82