27th Annual Sicomp Conference. Developments in applications and products for PET cored sandwich structures

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1 27th Annual Sicomp Conference Developments in applications and products for PET cored sandwich structures Stefan Reuterlöv GM Technical Service Armacell

2 Agenda Introduction to PET core material Armacell History Production r-pet High density PET PET foil PET profile? Conclusions

3 Armacell worldwide: 20 production plants in 13 countries on 4 continents Thimister (Belgium) Begur (Spain) Oldham (UK) Münster (Germany) / 2 Friesenhofen (Germany) Sroda Slaska (Poland) Brampton (CA) South Holland (US) Atlanta (US) Conover (US) Mebane (US) Spencer (US) Sao Paolo (Brazil) Dammam (Saudi Arabia) Pune (India) Bangkok (Thailand) Panyu (China) Souzhou (China) Cheonan (South Korea) Melbourne (Australia)

4 Innovation Sustainability Armacell was the first manufacturer to succeed in qualifying PET foam cores for industrial applications. Armacell is the only one making PET foam cores out of 100% post-consumer PET. Armacell uses state-of-the-art technology for production & quality control and complies with the stringent quality requirements of WTG industry. Today > blades globally are using ArmaFORM PET. ArmaFORM PET products are fully recyclable, 100% of material loss during production is re-used in internal recycling. No use of ozone-depleting HFC or CFC blowing agents and only halogen-free flame retarded additives are mixed. What Armacell stands for.

5 ArmaFORM PET - huge development potential and continuation of success!

6 ArmaFORM PET Foam Core Structural sandwich Strong in many areas Transport Train body Interior panelling in trains, buses, trucks, cars and camping trailers Wind Energy Rotor blades Nacelles Marine Boat hulls Cabin interior Sporting goods Infrastructures & Civil Engineering Cladding Panels Facades Bridges Other applications Aircraft parts & Cabin interior Skis

7 ArmaFORM PET the production process cutting Extrusion direction PET/E (extruded) bloc welding board slicing PET/W (welded)

8 High quality and consistency Constant raw material inspection using enhanced tools such as DSC (Differential Scanning Calorimeter) and Intrinsic Viscosity. 100% Inline Density Inspection on extruded boards. The information Is automatically feed back into the process creating very low density variation and excellent quality control. Inspection of compression, shear, tensile and flexion on welded boards. Full traceability to each raw material and extruder settings through imprinted block number and barcode. Unique Barcode per board! Comparison with original approved material. Visual inspection of the material and packaging. Every board is digitalized! Sample storage of min. 24 months. inline control density board thickness optical inspection

9 PET bottle collection rate EU: > 51% * Armacell s patented r-pet technology final application material collection sorting, crushing & baling Armacell has spent years of intensive research to develop a process technology that allows to produce consistent foam qualities from 100% post-consumer PET. board slicing shredding into flakes & washing 49% end up on landfills or waste our oceans. 15% mainly to incineration or landfill because of impurities. bloc welding internal granulation 36% recycled to new bottles, textiles etc. foam extrusion * source:

10 Eco-benefits based on foaming process Source: Eco-indicator 95 V2.1 Source: Eco-indicator 95 V2.1 Global warming potential (GWP) or carbon footprint measures the potential global warming impact of a process in CO 2 equivalents of greenhouse gases. Cumulative Energy Demand (CED) investigates the energy use throughout the life cycle of a good or a service. Source: LCA study, Dr. Justyna Dolega, Armacell 2013

11 Agenda Introduction to PET core material Armacell History Production r-pet High density PET PET foil PET profile? Conclusions

12 High density PET Increased interest in high density PET core, 200 and 250 kg/m3. Traditional applications are for inserts and areas with creep problems, transoms etc. Now we also see an interest in replacing balsa from other industries like wind blade applications, why??

13 High density PET Now we also see an interest in replacing balsa, why? Balsa has fantastic properties on paper but testing in 4-PB 3,50 Ultimate shear strength 3,00 2,50 2,00 1,50 1,00 0,50 0,00 Datasheet Plain Datasheet GS GR 250 Balsa

14 High density PET Now we also see an interest in replacing balsa, why? resin uptake in % proportional to PET PET 100 PET 115 PET 250 PVC 80 PVC 60 EGB So it is actually possible to infuse panels with better properties and lower weight using PET 250 than EGB

15 Agenda Introduction to PET core material Armacell History Production r-pet High density PET PET foil PET profile? Conclusions

16 Armacell s patented r-pet technology

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18 ArmaFORM PET Foil: product description 18 ArmaFORM PET FOIL = extruded PET foil (roll and sheet) 100% post-consumer PET closed cell temperature range: -40 C to 150 C (short term 180 C) fire performance: FMVSS302 (less than 100 mm/min) thermoform able (with wide thermoforming window) 100% recyclable oil, water, chemical resistant Process ability: Alternative to: Markets: thermoforming, vacuum forming, thermo compression, die cutting, lamination, thermo compression, flocking XPE, PP, cork etc. Transportation (Automotive, Train, Truck), Packaging, B&C, General Industry

19 Thermal stability Initial state After tempering at 170⁰C PET Foil Higher density 48h PET Foil Lower density 48h PP Foil 2h

20 ArmaFORM PET Foil applications non structural Door water shield; Chamber absorber Wheel arch-liner Engine bonnet insulation Air ducts acoustic layer

21 ArmaFORM PET Foil applications structural Underbody Trunk lining Wheelhouse Back panel Door panel (Hat tray) Rear deck panel

22 Agenda Introduction to PET core material Armacell History Production r-pet High density PET PET foil PET profile? Conclusions

23 ArmaFORM PET product family still to come ArmaFORM PET Profiles Applications Insulation: Filler in profiles Window frames Vibration dampening 3D shape Structural Stiffeners Mandrel for winding etc.... High temperature applications Superior insulation properties Compression strength

24 Agenda Introduction to PET core material Armacell History Production r-pet High density PET PET foil PET profile? Conclusions

25 Conclusions PET core material as such is still young with lot of new applications emerging: Today: increased high density (up to 250 kg/m3 but looking even higher) PET foil Recycled GFR 70 density in FST grade also based on 100 % recycled PET, more densit Tomorrow: Increased density range with lower density Next generation PET with finer cells and better properties PET profiles And more...

26 Thanks for your attention when do you start using ArmaFORM PET? Questions?

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