Direct Compounding Insight and results of the first full scale pilot plant

Transcription

1 Direct Compounding Insight and results of the first full scale pilot plant Matthias Graf Dieffenbacher GmbH+Co. KG, Heilbronner Str. 20, Eppingen, Germany, Dr. Erik Reuther DSM Composite Resins, Zeiloch 20, Bruchsal, Germany, Tobias Potyra Fraunhofer ICT, Joseph-von-Fraunhofer-Str. 7, Pfinztal, Germany, 10th ACCE, Sept 2010, Troy (MI)

2 Outline A cooperation with world-class partners Motivation The challenge A door opener Process development State of the art results Line control Specifically optimized resin systems Reference line at Fraunhofer ICT Conclusion and outlook

3 Cooperation of world class partners 1 System Partner 2 Resin Partner The leading manufacturer of system solutions in the field of forming Premium machinery systems Process & hardware development Turn key solutions Largest producer of structural resins in Europe Dedicated product portfolio & Composites Expertise Go Go 3 Research Partner Part of the largest organisation for applied research in Germany R&D Capabilities Process & Material development New applications & markets Go

4 Motivation for a new technology Grow into new applications and larger series sizes with Excellent quality consistency High degree of automation Total line control from compound to molded part Just-in-time production Flexibility for variable series sizes and broader range of new applications Short cycle times High efficiency

5 Idea Direct Process for the production of SMC parts in analogy to the LFT process (Long Fiber-reinforced Thermoplastics) Criteria of such a process are: High quality consistency Continuous process with constant time laps Complete control and monitoring of all process parameters Reproducible fiber impregnation Economical efficiency Saving process steps (storage, transport) High degree of automation

6 The challenge for a new technology Market needs Quality consistency High speed Cost efficiency High series lengths + Automation Just in time Complex parts Integration Large parts Extreme formulations New technology Quality consistency High speed Cost efficiency High series length Automation Just in time Complex parts Integration Large parts Extreme formulations The new technology extends the chances of Thermoset Composites in the market place to new applications and higher series lengths

7 A door opener for High series, complex and large parts, that can be found in... Trucks Solar Infrastructure Passenger cars Construction

8 D-SMC Line Configuration Mixing Extruder Glas Glass Rovings rovings Side feeder for filler + thickener Compounder Hydraulic Press Handling System

9 D-SMC Line Configuration Glass rovings Resinblender Compounder Cutting Unit

10 Dosing of liquid raw materials Gain In Weight dosing of liquid components Dosing station Raw material container GiW Batch Premix Batch Balance o o Dosing of max. 6 liquid raw materials with an accuracy of +-1g in a 10kg batch Viscosity range from 1mPa*s to 5000 mpa*s

11 Dosing of liquid raw materials Loss Of Weight dosing of premixed liquid components Premixed Batch Balance Dosing station Gear Pump for continuos dosing of resin additive paste o o Continious dosing of premixed resin additive paste into twin screw extruder Use of gear pump avoids pulsation

12 Performance of Reference Line Performance characteristics DIEFFENBACHER Reference Line Output of 2-8 kg/min (8 kg/min with sheet width of 800 mm and 4,5 kg/m² mass per unit area) Adjustable width of Compound of 400 mm mm Glass fiber adding between 20 % - 38 % feasible Mass per unit area between 3,5 and 4,5 kg/m² Production of Low Density SMC by containing glass microspheres Line control enables fast recipe changes

13 Mechanical Properties Low Profile Flexural strength, Strength Mpa 12 11,5 Flexural modulus, Modulus Gpa 11, SMC D- SMC Low Profile SMC Low Profile D-SMC strength, kj/m² Impact Strength 0 75 SMC D- SMC Low Profile SMC Low Profile D-SMC Glass fiber Low Profile SMC Low Profile D-SMC SMC D- SMC

14 Mechanical Properties Truck formulation Flexural Strength Flexural Modulus SMC D-SMC SMC D-SMC Impact Glass fiber SMC D-SMC

15 Mechanical Properties Extreme formulation Flexural Strength Flexural Modulus D-SMC Impact Strength Glass fiber D-SMC

16 Mechanical Properties Overview Flexural Strength Flexural Modulus D-SMC Impact Strength D-SMC Mechanical properties at different glass contents D-SMC

17 Line control

18 Possibilities of the line control Line control combines Direct Compounding equipment with cutting station, robot-assisted feeding and the press Individual recipes & formulations Dosing of up to 6 liquid and 6 solid components Recipe changes within few minutes Incorporation of all machinery components into one central control Central control enables to run and monitor the machine with 1 operator Central monitoring system with automatic alarm system

19 Resin development Based on its comprehensive resin and LPA knowledge DSM is developing resin systems specifically optimised for the Direct Compounding process Those resin systems reflect the needs and demands of the customers Everything is feasible Intelligently pre-mixed and easy-to-use resin systems adjusted to meet application specifications Extreme and unconventional formulations In either case, DSM will provide highly quality consistent top-of-the-line products to support the step into a new process technology

20 Reference line available at ICT since June 2010 For several years Direct Compounding was just a project in 2010 it is reality Dieffenbacher decided to install an industrial line at Fraunhofer ICT Since June 2010 the line is ready for use From this time on customer trials and developments will be performed on industrial scale

21 Conclusion and outlook A continuous process for Thermoset Compounding has been established Direct Compounding is a highly automated, computer-controlled and efficient process resulting in high quality consistency products The process of Direct Compounding will open new markets for thermoset compounds DSM will provide resin systems specifically adapted to the Direct Compounding process and the customer needs Reference line is available for customer trials and developments at ICT since June 2010 The 3 partners DSM, Fraunhofer ICT and Dieffenbacher will provide full support on the implementation of the Direct Compounding process

22 Team up with the market leaders in Chemical Technology - Resin Chemistry - System engineering