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10 Feb 2008  - 

2008 JEC Innovation Awards: and the winners are...

The JEC Group’s 2008 Innovation Awards Programme will reward eight companies and their partners on April 1st, 2008, during a special evening at the Louvre Museum. This year’s categories are Aeronautics & Space, Ground Transport & Automotive, Construction & Equipment, Energy & Industry, Environment, Process, Sports & Leisure, and Software.

Based on criteria for technical significance, marketing potential, originality, financial impact, and partnership complementarity, a jury of 15 international experts chose processes, applications and products that most successfully implemented a composite solution.

The 2008 Innovation Awards competition is supported actively by UMECO Composites, Official Partner, as well as several Gold Sponsors: Huntsman Advanced Materials (Aerospace category), Nanoledge (Sports & Leisure), SGL Carbon (Process), and Silver Sponsors: Cytec (Aerospace), Roctool (Process) and Polynt (Automotive).
JEC would also like to thank all its press partners: JEC Composites Magazine, Aviation Week, Journal de l'Automobile, Reference Industrie, TUT.

The 2008 finalists and winners are:

Category: AERONAUTICS & SPACE (4 entries short-listed)

Winner:
Resin-infused wing control surfaces for the Boeing 787, presented by Hawker de Havilland Aerospace Pty Ltd (AU), in partnership with Boeing Commercial Airplanes (USA), Boeing Phantom Works (USA), Spunfab Ltd (USA), Hexcel Reinforcements and Direct Processes Europe (FR).
This is the first time that this type of infusion process has been used on a commercial aircraft at such a large scale. All of the parts have been redesigned to suit the chosen technique. New materials had to be developed, including medium-weight carbon fabrics using 12K fibre.
The project covered North America, Australia, and Europe. It demonstrated that the choice of the Controlled Atmospheric Resin Infusion (CAPRI) process was a valid alternative to autoclave, eliminating the high pressure and temperatures previously required and reducing environmental impacts. The solution also allows the manufacture of complex, easy-to-repair parts, and easier management of raw materials in terms of handling and storage at ambient temperatures.
Industrializing the CAPRI process took thirty months. The materials were approved in July 2006, and production of the first parts began in December 2006. The first set of assembled structures was delivered in June 2007 for the roll-out of the first 787. The certification process is ongoing and should be completed by the first flight in 2008.
The process is designed for all of Boeing’s future aircraft programmes and derivatives.

Finalists:

Automated production line for the manufacture of composite preforms, especially for pultrusion application, presented by DLR Braunschweig (DE) with its partners Secar Technologies (AT) and EADS (France).
The resulting H-section profiles are used to assemble membrane-shaped carbon fibre reinforced composite (CFRP) parts. The profiles also have to be made of CFRP to ensure compatible thermal expansion coefficients. The line can produce the preforms 10 to 100 times faster than the existing processes, resulting in significantly lower costs. The lower costs will benefit the aerospace industry, but may also be extended to other application markets with other types of preforms.

Automated technology for the production of carbon-fibre preforms, by Eurocopter (DE) with its partners Aerostruktur Faserverbundtechnik GmbH (DE), Fischer (DE), University of Bayreuth (DE), University of Erlangen-Nuremberg Lehrstuhl für Kunststofftechnik (DE), Fraunhofer IIS (DE).
The technology involves making preforms by stitching and thermobonding prefabricated reinforcements together. The objective is to lower the costs of manufacturing by resorting less to manual operations. The process uses advanced stitching methods and a new thermobonding process. All this is made possible by the use of multiaxial non crimp fabrics (NCF). The advantages of this solution are lower costs, reproducibility, and flexibility for creating complex shapes.

Manufacturing of composite reinforcement frames for use in building an all-composite fuselage structure (composite skins), presented by Cytec Engineered Materials (USA), with Alenia Aeronautica (IT) and Cytec Engineered Materials (UK).
Until now, metal fuselages have been reinforced with spars, requiring assembly with hundreds of rivets. For carbon composites, this type of assembly is no longer possible, giving rise to the idea of using curved frames for the different fuselage sections. The frames are made from pre-infused braids and unidirectional prepreg fabrics into complex sections. It was necessary to develop two materials: a triaxial curved braid and a resin film to impregnate the braid.
The fuselage will consist of a series of frames of varying size.
The transition from a metal fuselage to a composite one requires reinventing the procedures, materials and structures. This is the objective of the project.

Category: GROUND TRANSPORT & AUTOMOTIVE (4 entries short-listed)

Winner:
Tailgate assembly for the new Smart models developed by Esoro (Switzerland) and Weber Fibertech (DE), with the collaboration of Smart GmbH (DE), ACTS GmbH & Co KG (DE) and Dieffenbacher GmbH (DE). The first industrial application for E-LFT (Endless-fibre-reinforced Long-Fibre Thermoplastic) technology, a one-shot mass-production process for structural parts. The continuous fibres provide excellent mechanical properties and can be placed along the load paths.
The assembly consists of a tailgate with a storage compartment and a hinged cover with visibly grained surface. Both parts had to meet crashworthiness requirements.
Compared to the previous solution, the parts meet higher rigidity and crash-resistance requirements, at 10% lower cost. Functional integration provides higher strength and additional storage area. The concept, which allows for great design freedom, uses low-cost materials (PP/glass fibre), but offers high crash resistance and lower weight compared to a metal solution.

Finalists:

Ambulance based on the design of a commercial vehicle (VW T5), presented by Composieten Team BV/FiberCore Europe BV (NL) in partnership with KVE Composites Group BV (NL), Terberg Specials BV (NL) and Deen Polyester Constructies (NL).
Built at the request of Holland’s Regional Ambulance Service, this new concept makes generous use of composites and thermoformed plastics, and stands out for its comfort, good human engineering, large interior and low maintenance costs.
Everything behind the driver has been redesigned. The load-carrying monocoque structure has doors and hatchback in RTM-moulded glass-fibre-reinforced polyester, with use of structural bonding. The lower panels are in thermoformed ABS/PMMA.
There are fewer parts, with a high level of functional integration that makes assembly fast and easy. Thanks to the electromagnetic wave transparency of composites, the antennas can be kept underneath the body surface.
The manufacturing process is ramping up, with 15 bodies already built by year’s end 2007.

Shieldstrand fibre and panels for ballistic and blast protection applications, presented by OCV (USA) in partnership with Composix Company (USA) and BAE Systems (USA).
A specific type of glass fibre was used to produce composite armour panels for the ballistic protection of armoured vehicles. This solution mitigates the effects of blast and fragmentation, thus ensuring effective ballistic protection, at lower cost than S-Glass or aramid, and lower weight compared to metal solutions. The panel was produced by Composix using phenolic resin and passed the MIL-PRF-64154 specification. A full armouring system with specific attachments was also developed. The fibre is mass-produced by OCV. Composix panels are already available. BAE is developing new explosion and blast protection panels that will be integrated into the vehicle design, thus saving weight. Military vehicles constitute the main market for the product.

Rear-seat structure for the M3 BMW car presented by Jacob Composite GmbH (DE) in partnership with BMW GmbH (DE) and Bond Laminates (DE).
The rear seat structure is made from a sandwich material that combines PP honeycomb with two woven glass/PP skins. Steel bearings are built in the structure. A one-step moulding process combining low-pressure and high-pressure forming was developed specifically for the project. The thermoplastic composite structure is produced in one step. The entire structure weighs only 6 kg (which is 6 kg less than a metal solution), but has very high crash resistance. The part development stage lasted 18 months, and production was launched in June 2007.

Category: CONSTRUCTION & EQUIPMENT (3 entries short-listed)

Winner:
Fire-insulation panels along with a full assembly and mounting system, developed by Ayres Composite Panels (AU) in partnership with Colbeck & Gunton (AU) and Thermal Ceramics (UK).
The focus was on fire-insulation properties that meet stringent International Maritime Organisation (IMO) and EU requirements, and provides a significant reduction in weight and installation labour costs. The panel design, based on an aluminium honeycomb with glass/epoxy skins, has one side covered with a layer of special intumescent insulating felt, and is further protected by a facing of treated glass fabric to provide a hard wearing and attractive surface finish.
The patented panels are the principal part of a passive fire protection system which is certified to IMO High Speed Craft (HSC) Code and EU Marine Equipment Directive (MED) requirements. The panels are mass-produced using a hot-press curing process. The development of the intumescent insulation felt, the installation system for mounting to the vessel structure, and fire testing,, was undertaken with strong involvement from the venture partners. On current large HSC ships, over 100 metres in length, an installed system weight of 4.5 kg/m² is typical, providing weight reductions of up to 75% or 30 tonnes
In the event of an uncontrollable fire on a vehicle ferry deck, the system is designed to maintain the structural integrity of the ship and escape routes; to protect upto 1000 passengers and crew, and to allow their orderly evacuation if necessary.


Finalists:

Large skylight for the roofs of certain types of buildings, developed by Industrial & Commercial Enterprises (IN) with Mechemco Resins Pvt Ltd (IN) and Epsilon Composite Solutions (IN).
The product is a translucent skylight that is 20 m in diameter, 3.3 m high and 6 mm thick, made in 36 identical sections for assembly. The process uses six layers of 450 g/m² chopped-strand mat with flame-retarded, UV-stabilized and solvent-free PE resin.
The self-supporting skylight is rapidly implemented; the structure is lighter compared to standard metal ones with glass or polycarbonate plastic plates and joints, meaning fewer stresses on the building. Because a single material is used, the structure is corrosion proof, leak proof, and expansion free.
The translucent structure saves on electricity, and also allows the use of decorative patterns.

Filament winding machine for large structures such as wastewater and chemical tanks, developed by Mariarkki Oy (Finland) and Sulmu Oy (Finland).
During the 2006/07 winter, very large tanks (8 m diameter, 20 m long) were produced for the nickel mine in Talvivaara (Finland). Given the size of the tanks, it was more cost effective to build them on site using the new machine design.
A specific feature of the machine is the fact that the mandrel is supported from one side only, allowing easy access and handling. The development of large bearings for wind turbines made it possible to manufacture a machine this size.
The machine was designed to produce tanks with a high glass-fibre content. Vinylester resin was used for the nickel mine application to provide resistance to highly acid liquids. The machine is easy to transport, making it possible to manufacture large parts on site.

Category: ENERGY & INDUSTRY (2 entries short-listed)

Winner:
High-field superconducting magnet for supercollider applications, presented by AGY (USA) with their partners A&P Technology (USA) and Accelerator Technology Corporation (USA).
The magnets consist of metal or ceramic superconductor coil windings made of very fine filaments. The required electrical insulation between the filaments is provided by glass filaments. In the case at hand, the superconductor is a ceramic and the glass filaments must be very thin.
The glass fibre used must meet the mechanical criteria and also withstand the entire coil manufacturing process, which includes a heat cycle. The filaments used are only 5 µm in diameter, so as to take up as little space as possible in the coil. A special non-heat-degradable sizing was used, with the right friction properties for processing and capable of withstanding temperature peaks during operation in case of unexpected quench failure. This required electric-insulating and heat-conducting properties.
A 5-µm-thick S-2 fibre was used with a high-temperature-resistant thermoplastic coating, a technology borrowed from the aerospace industry. It was necessary to adapt the braiding specifically to the requirement for electrical insulation by completely covering the ceramic superconductor. The assembly is held together with epoxy resin.
The filament and sizing have been developed and the material is available in quantity. This initial development phase was completed in response to a request from the U.S. Department of Energy (DOE) concerning the magnets for the future supercollider.
The scope of the application goes beyond this basic research need, however, encompassing magnetic resonance imaging (RMI) for medical purposes or the storage of electricity.

Finalist:

All-composite mail sorter system, entered by Globe Composite (USA) in partnership with the US Postal Service (USA).
This complete sorter system includes carriages, track, chain and actuator mechanisms, and is intended to replace traditional metal systems. Composite materials save weight, thus increasing the system’s throughput by over 50%. The components are stronger, requiring virtually no maintenance. The modular structure makes it possible to replace a line in 21 days, or 3 to 6 months faster than with the former design. The system allows a 12 dB noise reduction and 18-20% lower energy consumption.
Using composite materials will facilitate the use of RFID equipment (no interference). A significant market is opening up in the USA for the replacement of all sorter systems.

Category: ENVIRONMENT (2 entries short-listed)

Winner:
Basic moulding process using local agro-resources and minerals combined with a thermoset resin, developed by Agro-Resources Technologies (IN) with Sumangali Seva Ashrama (IN) and villagers and local people using this technological solution.
In India, a good part of the population is rural and constitutes an abundant source of inexpensive labour. Crops there generate considerable amounts of plant waste that, thus far, have been left unutilized. This gave the idea to use these two resources to manufacture objects using simple composite process and tooling to mould plant-fibre reinforcement and mineral fillers mixed with resin. Rather than taking place in a single large production unit, this is done by small, scattered units of three to four people. This very simple process uses a thermoset resin and simple moulds. The idea is to be able to make 10 to 20 objects per mould and per day, as a function of the part complexity. A finishing layer is provided for in order to produce smooth, sturdy, and waterproof surfaces. The objects made are small pieces of furniture, panels, construction elements, dishes, or even small boats.
This programme creates jobs and income in rural areas, eliminating the need for populations to migrate. It uses local resources and solar polymerization, so it requires very little electric power. The use of agro-resources is a way to be included in the global carbon credit trading system.

Finalist:

Moulding panels for private swimming pools using a compound that includes a high percentage of recycled thermoset resin. A solution presented by Ranger France (FR) in partnership with Menzolit (FR).
The originality of this thermoset compound moulding process resides in the formulation using 20-40% of ground-up recycled composite and the type of construction: the modular elements can be used to create different pool shapes. The process involves recycling a material that is not currently utilized. The current production makes use of factory production scrap. According to the company, the volumes of available thermoset materials will increase as more and more end-of-life vehicles are collected for recycling and with the sorting of demolition and dismantling materials. The project contributes to the waste utilization effort.

Category: PROCESS (3 entries short-listed)

Winner:
Electrically-heated carbon-fibre mould, presented by the University of Applied Sciences and Arts Dortmund (DE) in partnership with Fibretech Composites (DE), Yachtwerft Meyer GmbH (DE) and R&G Faserverbundwerkstoffe (DE).
This carbon-composite mould takes advantage of the electric conductivity of carbon fibre to combine the mechanical-resistance and heating functions. The original feature lies in the arrangement of the carbon fibres: while only the fibres in one direction receive electrical power, the perpendicular fibres also conduct electricity. The mould consists of a honeycomb sandwich with two quasi-isotropic skins, each made up of two carbon layers.
The mould retains high mechanical and dimensional stability during the thermal cycle, ensuring high dimensional accuracy of the parts manufactured. It is lightweight and cost effective. It allows energy savings and lower manufacturing costs.
The mould is intended for the production of large parts (wind turbine blades, ship hulls, etc.) and for short- to medium-run production. It can be manufactured using prepregs or standard resin/reinforcement processes. The University of Dortmund has established a licensing system to transfer the know-how. It also supplies complete production systems.

Finalists:

Autoclave with both microwave and standard electric heat, developed by DLR Braunschweig (DE), with Scholz Maschinenbau GmbH & Co KG (DE) and Fricke und Mallah Microwave Technology GmbH (DE).
Autoclaves serve to apply pressure and a certain level of heat to composite parts made of prepreg fabrics. The heat is provided by hot air, which is a relatively inefficient method of heat transfer, especially for large parts.
The heating method allows energy savings and the rapid heating process helps to cut down on production cycle times, resulting in overall cost savings. The greater efficiency of the process is favourable to the environment.
After validating the microwave process for autoclave heating of composite materials, DLR contacted its partners to develop a product for industrial use. When the application was sent in, the autoclave was in the in-house pre-certification phase and still needed to be certified for the aerospace industry. As soon as certification is obtained, the marketing phase will begin.

Megaject Patriot SSB meter mix machine for the RTM process, presented by Magnum Venus Plastech Ltd-RTM (UK) in collaboration with Magnum Venus Plastech (USA), Biobe AS (NO), Boston Whaler (USA) and Multina (USA).
The innovative feature is the intrinsically safe air-motorized catalyst ratio control. The machine combines the Patriot resin pumping system with the MotoCat catalyst metering system. The main advantages are the accurate resin/catalyst mix ratio and the easy adjustment of the catalyst percentage throughout the RTM process. Catalyst metering accuracy needs to be controlled, since it directly impacts the manufacturing quality of RTM parts.
The Megaject Patriot SSB has been launched in North America and will be officially introduced in Europe at the JEC Composites Show 2008.

Category: SPORTS & LEISURE (3 entries short-listed)

Winner:
2008 version of the WaveRunner SHO and HO personal watercraft using the lightweight NanoXcel composite material, presented by Yamaha Watercraft Group (USA) in collaboration with Yamaha Motor Manufacturing Corp (USA) and Interplastic Corporation (USA).
In this application, standard SMC materials are replaced with NanoXcel material, a new generation of low-density SMC. The new material is processed using the existing equipment and a slightly modified SMC technology. The parts concerned are the hull, deck and liner.
NanoXcel uses expanded nanoclay materials to replace calcium carbonate in a composite material with a urethane hybrid matrix. The new material constitutes a significant advance, since the other weight-saving solutions considered did not offer the required durability and strength.
The new formulation has an improved moulding flow capability, thus improving surface finish, reducing defects in the painted parts, and minimizing subsequent rework. The final parts offer improved surface finish, 25% weight saving and increased strength. The weight saving contributes to a better-performing craft, with faster speed and acceleration, and lower fuel consumption.

Finalists:

Rotagrid and Rovispace reinforcements used to manufacture skis, developed by Chomarat (FR) and its partner Dynastar.
These are flat or thermoformed glass/epoxy reinforcements that are designed to confer specific properties to the ski, such as longitudinal stiffness or torsional strength, without adding weight and without interfering with the manufacturing process.
The idea is to improve skiability, i.e. confer the adequate properties (trajectory precision, flexibility and stiffness, torsion, etc.) that will be needed during use.
The scrim form of the reinforcements facilitates PU foam injection. Rotagrid has the advantage of being able to hold the top surface in place temporarily during the moulding process.
The products provide improved performance at lower cost. They are easy to use, saving time during the manufacturing process.

The Parasol, developed by Mobile Lockers Services (FR) in partnership with Eurl Patrice (FR).
Many outdoor activities require participants to change into sports gear and store their clothes and bags for a few hours. This need is very poorly met at beaches and during occasional sports events.
The Parasol is a cylinder that can be installed on the ground. It contains 45 lockers and has an overhanging kiosk-type roof that also serves as a rudimentary shelter. Since it is meant to stay out of doors in the sun and rain, sometimes on beaches in a saline environment, composites were a natural choice for the materials. The definitive surface aspect is either the unfinished composite or a printed fabric under a transparent gelcoat.
Attractive finish, sturdiness, low maintenance (easy cleaning), low weight and corrosion resistance are its major advantages.

Category: SOFTWARE (4 entries short-listed)

Winner:
Precimould tool design software, presented by Advanced Composites Group (UK) and its partners LUSAS (UK) Ltd., BAE Systems Plc (UK) and Bombardier Aerospace (UK).
Precimould makes it possible to design the shape of tool surface required to produce a finished part as close as possible to the required size and shape. This software tool is used within the Lusas finite element code. It was designed so that an experienced CAD operator can quickly learn how to use Precimould without an extensive background in finite element analysis.
The software tool reduces processing distortions that cause part inaccuracies or non-compliances resulting in poor fits during assembly.
The development stage took several years. The first step consisted in understanding the part distortion process and identifying the parameters involved. The subsequent software design process included an extensive study of material properties and behaviours. Finally, the software was validated by comparing modelling data with experimental measurements.
The product is being launched in three areas: sale of licenses to composite tool and part designers, use of the tool within ACG and FEA for consultancy work, and use by ACG to produce optimized tools for their customers.

Finalists:

Digimat design software platform for composite parts, presented by e-Xstream Engineering (BE) and their partners Rhodia Polyamide (F) and Trelleborg (F).
Digimat is multiscalar (from the microstructure to the entire part) rather than linear. It uses the matrix, reinforcement, microstructure and morphological properties to infer the thermomechanical behaviour. The platform consists of six modules that correspond to the different part features, constituent materials, and mathematical and physical laws employed. It is a bit like a virtual laboratory for anticipating a material’s macroscopic behaviour and studying microstructure and damage. The software is interfaced to most structural analysis programs and injection moulding programs.
The idea is to use computing and analysis to go as far as possible in the design of parts and in the exploration of different variants to avoid wasting more than the time it takes to compute, before launching real-life experiments on prototypes that involve mould fabrication.
The main benefits are: weight savings, reduced costs, easier manufacturing (moulding), greater design freedom and functional integration.

PlyMatch, a visual aid system for manual ply placement in the production of composite materials, developed by Anaglyph Ltd (UK) and NPL National Physical Laboratory (UK).
The system combines a digital camera, a PC and a placement software program to facilitate the manufacturing process. It is much cheaper than laser projection systems.
The system displays on a computer screen a live video image of the “assembly scene” (mould, current ply, operator’s hands), overlaid by a computer-generated image of the mould and the composite ply being laid in its correct position in the mould. This manufacturing aid is affordable for small- and medium-sized businesses. It features accurate ply positioning and trimming, flexibility, and ease of use. The system can work with direct CAD file input or with Anaglyph’s Laminate Tools software.
The product will be presented again at the JEC Composites Show 2008.

RTM Process 2, a software program for small- and medium-sized firms and suppliers looking for help in developing a manufacturing process using RTM, infusion, and compression moulding, presented by PPE Pôle de Plasturgie de l’Est (FR) and LDB (FR).
The software includes a number of modules for preliminary mechanical dimensioning, simulation, technical and economic assessment, choice of the most suitable process, and structural dimensioning of tooling. It also includes a materials database module and an assembly-method selection matrix.
The software uses the materials database to simulate all development phases for a composite structure. It gives an initial view of a given project and allows making rapid conclusions. The materials database includes generic data, data supplied by partner companies on their products, and data entered by the user. The software is fully developed and will be presented at the JEC Composites Show 2008.

Special mention from the JEC Composites Magazine

The first light aircraft made in France by infusion moulding, and the first one-piece, self-stiffened carbon/epoxy fuselage for a light aircraft.
The Brest institute of technology (IUT) sent in an application in the Aerospace category. The decision to give prominence to this project was based on its atypical nature (originating from an educational institution rather than a business company) and various noteworthy aspects.
The partners were Gazechim (FR), The University of Nantes (FR), HDS Structures (FR), Composites Distribution (FR), Axson (FR), Structil (FR), Rex Composites (FR) and Oseo (FR).
The project was designed as an educational one, to allow students to come into contact with industrial realities. More than 70 students have already worked on the project, helping to transfer knowledge about composites into the industrial environment.
Industrial firms have given a token of confidence by participating in the project financing in exchange for the technological know-how. The fact that technology is being transferred to the firms is an indication of the reliability of the work carried out.

It’s time to think about the 2009 competition !

Companies all over the world involved in composite innovation (whether they are JEC Composites Show exhibitors or not) can submit their applications online at www.jeccomposites.com/innovation from April to November 2008.

Source : JEC