Class A surface finishing of composites via Powder In-Mold coatings

Transcription

1 SPE ACCE Detroit, Sept A BETTER FINISH. FOR A BETTER WORLD. Class A surface finishing of composites via Powder In-Mold coatings by Dr. Thomas Schmidt

2 TIGER Coatings GmbH & Co. KG with worldwide about employees global network and development strategy agencies in 40 countries 10 powder coating manufacturing sites worldwide 3 R&D-centers(Europe, NAFTA & China)

3 Worldwide Network

4 TIGER Powder Coatings TIGER Drylac Value Propositions/ Integrated System Solutions Powder coating systems for metal and novel substrates Specialisationon innovative substrates, likecompositematerials, magnesium, glass& wood(mdf) Metallic and special effect coatings

5 Opportunities for In-Mold Coatings Fibers Materials: Glass Carbon Aramid Natural Fibers Resulting Fiber Reinforced Plastic (FRP) SMC/BMC CFC Heat Resistant Composites WPC, etc. Surface Defects

6 Opportunities for IMC Fiber Reinforced Plastic (FRP) Fast Production Processes Liquid Injection Molding Prepreg Process RTM VARTM Press Autoclav

7 Powder In-Mold Coatings - the idea 1. Spray powder in mold 2. Melt and (semi-)cure powder 3. Insert fiber material 4. Close mold (and inject resin) and cure powder and resin 5. Unload IMC coated composite material Result: No surface defects! Ready to overcoat! Clear top coat!

8 Powder versus Liquid In-Mold Coatings Feature Powder Liquid Solvent Emission no yes Smell no yes Edge coverage Very good poor Electrostatic application yes no Work Safety Very good Poor Robustness Very good good

9 Powder In-Mold Coating versus Standard Coating System Feature Powder IMC Standard paint application Cost low very high Coating layers filler layers, Emission no yes top coating Edge coverage very good poor, multi layers needed Smoothness very good poor, sanding of fillers required Robustness very good intercoat adhesion and chipping resistance questionable

10 Porsche Carrera GT Project Class A surface via powder in-mold coating! Reference Project: Mold was powder coated at temperatures of 120 C Carbon-prepregs were inserted in mold at temperatures of 50 C Curing process: 40 min at 120 Powder coating: highly-reactive epoxy/polyester hybrid Coating thickness: ~150 µm

11 RTM Test Tool Powder In-Mold Clear Coat

12 Powder In-Mold Coated Surface Powder Coating Glass Fiber and Resin Powder In-Mold Coating fills up all surface defects and levels out uneven surfaces!

13 Powder In-Mold Coated Surface - coating thickness between µm adjustable - powder is filling unevenness (pores, uneven woven fiber surfaces, other defects) - very good adhesion between the powder coat and the composite resin, chemical bonding between powder-resin & impregnation resin

14 Powder In-Mold Coatings State of the art External Release Agent Long cycle times > 60 min High temperatures ( C) Small series only SMC CFC High value applications Future Internal Release Agent Short cycle times < 15 min Low temperatures ( C) Large volume manufacturing RTM GFC and CFC Cost efficient composite components for mass production Target: Non-defect composite sufaces for Class A top coatings!

15 State of the Art Powder Reactivity Short Curing Times Development Strategy Low Curing Temperatures

16 Shorten Curing Times Development Strategy Result: Short cylce times enabeling mass production Lower Curing Temperatures

17 Building the bridge together - today

18 Building the bridge together - tomorrow

19 Transformation from handicraft style manufacturing to fully automated industrial production required.

20 Key success factor is working in networks! Close cooperation with automotive and aircraft OEMs machine and equipment manufacturers raw material suppliers composite manufacturers

21 IMC R&D Projects Seltec FFG -Take off

22 IMC R&D Projects RTM-IC FFG-COIN Hämmerle & Vogel

23 Powder In-Mold-Coating FAB analysis Feature Advantage Benefit Solid Powder Chemically cross-linked No solvent emission and No smell Low CO 2 footprint Overspray can be reclaimed Robust surface Very good adhesion Safe and healthy Workplace Environmental friendly High material efficiency Long life time of products Highly reactive powders Short cycle times Cost savings Mass production possible Electrostatic application Non-porous surface Good edge coverage Little overspray Easy to apply top coat, no filler and no sanding Required Less work in progress No defects Economic process Cost savings High process reliability Automated powder spraying guns available Fast industrial process possible Mass production possible Cost savings

24 Intellectual Property - Copyright Thank you for your attention!! Muito Obrigado! 有難うございました! Merci Mille Fois! Muchas Gracias! Danke für Ihre Aufmerksamkeit!!! TIGER Coatings GmbH & Co. KG 2009 Attention Please - This presentation is protected by copyright. Any disclosure, public presentation or the use of images or text require the authorization of the author and must bear the above copyright notice. It is also forbidden to make this presentation via the Internet or in PDF format accessible to the public. For inquiries or any further information please contact Diese Präsentation ist urheberrechtlich geschützt. Jede Weitergabe, öffentliche Vorführung oder die Verwendung von Bildern oder Texten bedarf der Genehmigung durch den Urheber und muss den oben aufgeführten Copyright-Hinweis tragen. Es ist zudem untersagt, diese Präsentation via Internet oder als PDF öffentlich zugänglich zu machen. Für Nachfragen oder eventuelle weiterführende Informationen stehen Ihnen folgende Quellen zur Verfügung: TIGER Coatings GmbH & Co. KG Negrellistraße 36 I 4600 Wels I AUSTRIA T +43 (0)7242/400-0 I F +43 (0)7242/ office@tiger-coatings.com