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JEC Group unveils the winners of the JEC Innovation Awards at JEC Forum Chicago 2019

29 May 2019
The JEC innovation awards is a long-established and worldwide program with 3 simple goals: identify, promote and reward the most innovative composite solutions in the world.

The JEC innovation awards is a long-established and worldwide program with 3 simple goals: identify, promote and reward the most innovative composite solutions in the world. Over the past 15 years, the JEC Innovation Program has involved 1,800 companies worldwide; 177 companies and 433 partners have been rewarded for the excellence of their composite innovations. The JEC Innovation Awards reward composites champions, based on criteria such as partner involvement in the value chain, technicality or commercial applications of innovations.

« Every year, JEC rewards the best cutting-edge and ingenious projects using composites to their full potential in different categories. The JEC Innovation Awards program is emblematic and recognizes pioneers in composite innovation continuously reinventing the composites of tomorrow», says Franck GLOWACZ, Innovation Content Leader at JEC Group.

The JEC Forum Chicago innovation awards winners will be rewarded on June 19th at 5:15pm for their innovative solutions, divided in categories: Mobility, Building, Automotive and Infrastructure. Dirk AHLBORN - Co-Founder & CEO, Hyperloop Transportation Technologies will introduce the ceremony with a keynote speech on “Transforming Transportation at the Speed of Sound” and Peter Hopwood, Public Speaking & Pitch Coach, will host the overall ceremony.

Join us at the Innovation Awards Ceremony
on June 19 at 5.15 pm
at JEC Forum Chicago in Aon Grand Ballroom,
Navy Pier
www.jec-chicago.events

Mobility

FMC for the KTM Carbon Skid Plate

FMC for the KTM Carbon Skid Plate

FMC for the KTM Carbon Skid Plate

Winner: KTM-TECHNOLOGIES GmbH - Austria

www.ktm-technologies.com

Partners: Mitsubishi Chemical Carbon Fiber and Composites GmbH (Germany)

The new hybridized Carbon Skid plate is made for motorcycles and was successfully developed to serial production together with KTM-Technologies, Mitsubishi Chemical and KTM in a short time and produced in a 1-shot serial production (cycle times <4 minutes). The composite look is created by using Carbon forged molding compound (FMC) for the main part, non-crimped fibers (NCF) for local reinforcements and elastomers for local damping. Due to this newly developed engineering process, we are pushing the boundaries within the composite market. Combining the named materials in 1 fully automated process step enables a new generation of sustainable composite structures which have huge design freedom

The joining is built by direct chemical bond between different thermosets and elastomers without need of additional joining processes. This easy production also allows the manufacturing of most of materials and parts in one place which saves transportation, emissions and time. This hybridized part with a refreshing Carbon look leads to a best fit to market compared to current skid plates made of aluminum, CFRP-fabrics or plastic. It is as light as standard CFRP solution (lighter than plastic, aluminum) but 50% cheaper. Testing and real-life showed that the mechanical properties are also better for this application. Based on this new material data were created which can be used for simulation and development of other structural parts on market. The result is a structural, complex part that fits to market needs by saving time, costs and efforts. This new circle of sustainability leads to structural components with new material cards where the usage of less unidirectional carbon fiber helps to save energy drastically, e.g. no exact pattern needed. The used carbon fiber will be recycled into fleece or short fiber reinforcement for the thermoplastic materials. This innovation combines new composite design, efficient solution package and breakthrough serial production technology.

Key Benefits:

  • New look with best fit to market in properties & costs compared to current parts
  • Creation of material cards of new hybrid material mixes
  • Complex hybrid part manufactured in time saving 1-shot process (< 4min)
  • Reduced CO2 emission because of direct production with less transport effort
  • Reliable because calculated, tested, and proven in real-life use case

 

 

Building

Contribution of nanotechnology in composites for an avant-garde architectural design

Contribution of nanotechnology in composites for an avant-garde architectural design

Contribution of nanotechnology in composites for an avant-garde architectural design

Winner: GAZECHIM COMPOSITES IBERICA - Spain

www.gazechim.es

Partners: Chomarat (France), Graphenano Composites (Spain), Owens Corning (Italy), Chem-Trend (Germany), Euromere (France), Gurit (Germany), Look Composites (Spain), Nouryon (The Netherlands), Obo (Germany), Omar Coatings (Spain), Polynt Composites (Spain), Polymec (Spain), Talleres Xúquer (Spain)

Enabled by the design flexibility and superior aesthetic characteristics enabled by Composites, this impressive team designed, developed and implemented a fully- reimagined, a large, avant-garde design-inspired canopy and other architectural elements, like shade slats for Gazehim Composites logistics headquarters building in Valencia, Spain. The flagship element in the building is a self- supported huge canopy. This structure leverages Graphene-based nanotechnology with a total surface area of 340 sqm and resembles the hard top of a boat where concepts from naval architecture are transferred to civil architecture.

This effort marks the first Construction application featuring nanotechnology in polymeric matrix to enhance Composite performance. This matrix has been doped with graphene to enhance the properties of flexural modulus and tensile strength, while also reducing the overall weight of structures. Total surface of other implemented GRP elements is 275 sqm in the office’s façade and 880 linear meters of profiles for shade slats. In addition, around 3000 linear meters of Graphene doped GRP rebars have been used to reinforce the concrete of some areas of the project

Key Benefits:

  • Demonstrate the design freedom, flexibility overall advantages with composites
  • Highlight the impacts of Graphine nanotechnology to improve key properties
  • Showcase the future of construction in architecture
  • Feature a highly industrialized manufacturing and implementation process
  • Highlight the ongoing innovations in Composites

 

 

 

 

 

 

Automotive

Thermoplastic Overmoulding for Auto Applications

Thermoplastic Overmoulding for Auto Applications

Thermoplastic Overmoulding for Auto Applications

Winner: Surface Generation - United Kingdom

www.surface-generation.com

Partners: Engenuity Ltd (UK), InCA Technology (Switzerland), K.D.Feddersen UK Ltd (UK)

The composite C-Pillar reinforcement component, designed by Engenuity Ltd (ENG) and manufactured by Surface Generation Ltd (SG), exploits the principle of thermoplastic overmoulding to achieve a step change in structural performance of the vehicle body-in-white (BIW). That is, to make judicious use of high performance, aligned, continuous fibre reinforced material only in localised areas where load paths demand their use, thus minimising the overall part cost. Elsewhere, more affordable short fibre reinforced material is used to realise complex features that add part stiffness through geometry and enable assembly.

The component possesses complex geometry and variable thickness (2mm to 8mm). It comprises four inserts of continuous fibre (CF) reinforced PA6 (SGL Group, Sigrafil C T50) overmoulded with a short fibre (SF) reinforced PA6 compound (K.D. Feddersen, AKROLOY PA ICF 40). The component is adhesively bonded to the BIW after its e-coat process. The CF inserts are stamp formed from a pre-consolidated organosheet produced with a highly orthotropic laminate stacking sequence to suit the in-service loading of the component.

The moulding surfaces of the forming tools are adjusted, using output from analytical studies conducted by SG, to compensate for process induced distortion. The CF inserts are positioned in the overmoulding tool. The tooling is designed and manufactured by SG and incorporates their patented “PtFS” thermal control technology. The tooling is closed and each of the 96 heater/cooler channels are zoned and their thermal cycle optimised. The component is cooled partly in mould and partly within an external fixture. SG and ENG worked together to develop test methods that would enable the optimum process conditions to be established in relation to the bond strength between the overmoulding material and the continuous fibre reinforced inserts. PtFS technology was exploited to achieve the necessary thermal conditions prior to overmoulding.

Key Benefits:

  • Lightweight – a 30% mass saving over the state-of-the-art metallic solution
  • Affordable – a net edge moulded composite part at €19/kg
  • Recyclable – recovered fibre supporting a material suited to reprocessing
  • Adoptable – a design solution creating opportunities for platform variants
  • Transferable – technology benefitting both industry and consumers

 

 

 

Infrastructure

CL Solid CFRP Bridge Cable

CL Solid CFRP Bridge Cable

 

Winner: Carbo-Link AG – Switzerland

www.carbo-link.com

A solid CFRP tension member designed to link any two parts of a bridge superstructure. Facilitating exact property characteristics combined with custom interfaces to suit any supporting infrastructure. CL Solid CFRP Bridge Cable is driven by stiffness and break load demands - whilst both variables are treated independently. The inherent non-corrosive nature of carbon is further enhanced with a ceramic coating to increase resistance to chafe, impact and further vandalism. Stiffness demands drive the selection of the applicable raw carbon fibre and matrix material, whilst break load demands drive the fitting size and form (considering many variables given the interface to the bridge superstructure).

The CL Solid CFRP Bridge Cable is produced from prepregnated tapes and titanium fittings. Raw carbon fibres are impregnated with the optimum matrix material using our in-house, automated prepreg machine. This process ensures that the carbon fibre filaments are aligned perfectly along the load path - ensuring exacting stiffness. In addition, the prepreg tapes are produced to the correct width to correspond with the titanium termination, meaning there are no slit tapes along the entire length. Custom laminate plans are engineered for each cable, defining the number of loops, start and ending points of the tapes. The prepreg tapes are wound around the titanium thimbles in accordance to the laminate plan before being consolidated into a circular form on an automated winding machine. After consolidation, the cable is put under a predetermined load and held under tension whilst being ‘cured’. The curing occurs ohmically, with electricity, or in an oven. The hot melt matrix system goes soft at a certain temperature during the curing process, this allows the prepreg tape to relax which further straightens the fibre along the load path.

Key Benefits:

  • Superior fatigue properties; reduced stiffness, consistent load distribution
  • Superior durability and corrosion resistance in harsh exposure environments
  • Weight saving; lightweight cable and reduced demand on support infrastructure
  • Significant reduction in cost of ownership; install logistics & maintenance cost
  • Competitively priced to inferior steel alternatives; less material required

 

 

The winners of the 2018 JEC Forum Chicago Innovation Awards

 

The winners of the 2018 JEC Forum Chicago Innovation Awards

The winners of the 2018 JEC Forum Chicago Innovation Awards

 

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About JEC Group

JEC Group is the world’s leading company dedicated entirely to the development of information and business connections channels and platforms supporting the growth and promotion of the composite materials industry. Publisher of the JEC Composites Magazine - the industry’s reference magazine, JEC Group drives global innovation programs and organizes several events in the world, including JEC World (the foremost and world-leading international exhibition dedicated to composite materials and their applications), which takes place every March in Paris.

www.jeccomposites.com