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CCE-JEC Innovation Award 2020

News International-French

3 Sep 2020

In order to boost technology innovation and energy saving in Chinese composite industry, to promote new products development and application, a new products area had been established since 2003 at China Composites Expo, especially the CCE-JEC Innovation Awards became a highlight when it was set up in 2005.

CCE-JEC Innovation Award 2020
For the 16th year in a row, the CCE-JEC Innovation Awards Programme was a huge success. For 2020, 9 composites solutions were rewarded for their innovation by the jury.

For several years now, JEC Group has been forming alliances with China Composites Group Corporation Ltd (CCGC), which organizes the China Composites Expo trade show.

For the 2020 edition, the winners are...
 

Part 1 - RAW MATERIALS

  • SYT65 Super high strength carbon fiberZhongfu Shenying Carbon Fiber Co., Ltd.

SYT65 Super High Strength Carbon Fiber - Zhongfu Shenying Carbon Fiber Co., Ltd.
SYT65 carbon fiber with higher tensile, high elongation at break, excellent stiffness, good processability of filament-winding, can meet  composite parts,which have higher requirements on performance. The product is widely used for aerospace, higher grade sports application. Production Place: Lianyungang, Jiangsu Province, China.

Innovation points:

1. Creative and innovative preparation technology for polymer pregnant solution with high molecular weight, high intrinsic viscosity and higher uniformity. Proceed from preparation of macro-molecule polymer and distributed control of molecular weight, solved the key issues of viscosity increment, decreased spinnability and filtration difficulty caused by increase of molecular weight.

2. Overcome key Dry-Jet Spinning process technology of PAN precursor used for super higher tensile carbon fiber. In term of spinning  & configuration, optimizing process operation and improving uniform of fiber structure on the aspects of sizing protection, orientation of fiber, make further efforts to improve performance of carbon fiber.

3. Research and development of fine control over fiber structure under process of pre-oxidization & carbonization. By improvement of heat dissipation efficiency, reduction of fiber etching under the environment of high temperature and oxidation, decrease physical damage to fiber, adjust micro structure and defects of fiber to improve performance.
 

  • Fiber Plastic Composites (FPCs) - Sino Polymer

Fiber Plastic Composites (FPCs) - Sino Polymer
FPCs can be used in many fields:Production and logistics: pallet and truck partitions. Gardens and outdoor landscapes: flower stands, flower boxes, leisure chairs, walkways, railings, bridges, pavilions, etc. Municipal engineering: garbage sorting room, garbage bin, bus station, mobile toilet, etc. Business office: conference tables and chairs, product display cabinets, exhibition booths, etc. Production Place: Suzhou, Jiangsu Province, China.

Innovation points:
1. FPCs are made of polyester, cotton and other hybrid fibers and a thermoplastic matrix. Through a process independently developed, a new "homogeneous reinforced" composite material is made. At the microscopic level, fiber-plastic has formed a designable fiber-reinforced network structure with good physical and chemical properties.

2. FPCs need to help deal with and digest all kinds of mixed textile solid wastes. Therefore, in all aspects of raw material processing and production processes, the technical difficulty is far greater than wood-plastic. To this end, the project independently developed a multi-stage dispersion and conical twin-screw extrusion process.

3. Environmental protection at the source. Use waste textiles (solid waste) to replace wood flour and protect forest vegetation.

4. Good weather resistance and long service life. Fiber-plastic composites is significantly better than WPCs, it is more suitable for outdoor environments exposed to wind, rain, and sunlight, and has a longer service life.

5. Better toughness. WPCs is brittle and easy to break; while FPCs has good toughness and is not easy to break.

6. Elasticity and good walking comfort. Fiber-plastic elasticity is better than wood-plastic, and it is used on outdoor trails to protect ankles and knees of walkers. If the elderly and children accidentally fall, the injuries will be less.

7. Good sound absorption and low impact sound. This feature is suitable for applications such as panel houses, floors, and building partitions.

8. Good nail holding power. After actual testing, the grip strength of FPCs is significantly better than WPCs. As a keel material, it can eat iron nails, and the wood-plastic keel often has a separation between the planking and the keel.

9. Strong drop resistance. During the transportation of wood-plastic, cracking and edge collapse sometimes occur. FPCs has better  resistance to beating and can withstand the test of logistics transportation and on-site assembly.

10. Thermal expansion and contraction, not easy to deform.

11. Lightweight. FPCs is 15% lighter than WPCs. On the one hand, it is easier to transport and move, on the other hand, it saves more raw materials.
 

Part 2 - NEW APPLICATIONS

  • Integrated design and rapid prototyping of CFRP auto body parts - Chongqing Changan Automobile Co., Ltd.

Integrated Design and Rapid Prototyping of CFRP Auto Body Parts - Chongqing Changan Automobile Co., Ltd.

These three parts is integrated into the national key R&D project "integrated development technology of light weight pure electric car". The CFRP pure electric car meets the requirements of the new version of C-NCAP five-star collision, and achieves body weight reduction of 31%. Furthermore, the integrated design of CFRP parts and the application of rapid prototyping technology can be extended to the field of new energy vehicles. Production Place: Chongqing, China.

Innovation points:

1. This is the first time to realize the forward design and integrated application of three typical rapid prototyping processes: rapid prepreg molding, HP-RTM and thermoplastic prepreg molding on the same vehicle. The CFRP car body developed by this project meets the five-star collision requirements of the new version of C-NCAP.

2. This is the first CFRP front floor developed based on prepreg molding process in China. The original 11 steel parts are integrated into one part. The weight loss of single piece is 9.8kg, the weight reduction rate is 59.2%, and the molding cycle of rapid prepreg is  8.6min/piece.

3. The performance of A-pillar inner plate is optimized by local strengthening layer, the weight reduction rate reaches 52%, and the molding cycle reaches 4.7 min/piece by HP-RTM process, which is in the domestic first-class level.

4. The roof beam molded by thermoplastic prepreg molding, and the cycle time is 7min/piece, which opens up a new idea for carbon fiber recycling.
 

  • CFRP rear floor assembly - Langfang Feize Composites Technologies Co., Ltd

CFRP rear floor assembly - Langfang Feize Composites Technologies Co., Ltd
Carbon fiber rear floor assembly is used in electric vehicles (BEV) and hybrid electric vehicles (HEV) or plug-in hybrid electric vehicles (PHEV), which can significantly improve the torsional stiffness of the vehicle. Production Place: Langfang, Hebei Province, China.

Innovation points:

1. High efficiency. With multi-cavity mold and fast cure resin, the cycle time is reduced to 90s.

2. Fully automated bonding & assembly line. Multiple bonding & assembly technology are applied in this line. The cycle time of bonding & assembly (with a lot of bonding of metal parts and studs) is within 5 mins thanks to the reasonable layout design and process design. 3D visual online monitor system and 2D photograph system are applied to the key process of the line to guarantee the stability and  consistency of the quality.

3. Low cost. With special nesting system and stacking technology, the scrap rate of the fabric is largely reduced. Optimized milling process and the introduce of cutter reuse technology enable us to largely reduce the milling cost.

4. Innovative quality control method. Combine the quality control method of automotive industry and the quality control method of the  aerospace industry and develop a innovative quality control method for the mass production of CFRP parts.
 

  • The rear pressure bulkhead dome of Φ4m by AFP process - Hiwing Materials Industrial Co., Ltd.

The rear pressure bulkhead dome of Φ4m by AFP process - Hiwing Materials Industrial Co., Ltd.
The Rear Pressure Bulkhead dome can be applied to the various types of aircraft structures, and the corresponding forming technology can be widely extended to various large-scale composite structures in the aerospace industry and the shipping industry. Production Place:  Suzhou, Jiangsu Province, China.

Innovation points:

1. It is the first time in domestic that the large-size composite dome structure was manufactured by female mold.

2. It is the first time in domestic that the fiber placement path planning was developed for net forming the large-curvature structure with dense grille.

3. It is the first time in domestic that the forming process and the structural design were taken as a whole in searching for their optimal matching and harmonizing with each other for engineering application.

4. It is the first time in domestic that the process accuracy and repeatability with continually high frequency tow cutting and re- transmission.

5. It is the first time in domestic that the feasibility of the AFP process program was verified for the large-size and equal proportion grid stiffened composite dome with completely typical structure.
 

  • Sinoma85.6 offshore low-cost full glass fiber wind turbine blade - Sinoma Wind Power Blade Co., Ltd.

Sinoma85.6 offshore low-cost full glass fiber wind turbine blade - Sinoma Wind Power Blade Co., Ltd.
Sinoma85.6 is suitable for Class S and 6.45MW/8MW series offshore wind turbines, which is a key component of wind power generation equipment and is a key factor in achieving low power costs. Production Place: Funing, Jiangsu Province, China.

Innovation points:

1. Design technology: In order to achieve serial production of blade, from the shape to the mold tooling design, the first consideration is the blade family Design; The material system used is the glass fiber epoxy resin system to reduce material costs; The structural version used is the eggshell single-layer skin design technology to reduce blade design weight and blade cost.

2. Blade performance: The aerodynamic design is based on the characteristics of the highly corrosive blades at high sea salt  concentration. Considering the roughness of the blade in the design, the design is closer to reality and the performance is more  conservative; Based on the characteristics of offshore operating environment and high-cost of maritime maintenance, Advanced anti-corrosion technology and LSP technology are used to improve the adaptability of the blade in harsh environments.

3. Process: The number of main girder layers is currently the largest among the company's full glass fiber blades. Using an integrated infusion process, this is a breakthrough in the company's process technology. For the first time, the forming method of circumferential spreading is adopted, and it is successfully applied to the blade, which solves the difficulty of traditional axial layering on large blades.

4. Certification: Structural DAA certification is carried out simultaneously during the design and development process, which effectively controls design risks and speeds up the certification process; Carry out the world's first pneumatic DAA certification with DNV GL, fully evaluate the aerodynamic performance of the blade, and promote the power generation revenue of customers and owners.
 

  • HFFP synthetic sleeper - Tieketengyue Technology Co., Ltd.

HFFP Synthetic Sleeper - Tieketengyue Technology Co., Ltd.
HFFP synthetic sleeper can be applied to the passenger and freight common lines with curve radius not less than 295m on the open deck. The maximum design speed of train is 200km/h, and the maximum axle load is 270kN. Production Place: Shijiazhuang, Hebei Province, China.

Innovation points:

1. High strength. The bending strength is more than 200MPa, and the bending load of finished bridge sleeper is more than 1400kN.

2. Good durability. The retention rate of bending strength, compression strength and shear strength of HFFP after weathering, salt spray aging and heat and humidity aging is more than 80%. After the fatigue load of 67.5kN~337.5kN repeatedly acts for 2 million times, it has no abnormality. The service life is expected to be at least 50 years.

3. Strong ability to control the spikes and can effectively maintain the track geometry.

4. No water absorption, good insulation and fire resistance.

5. Good processability and repairable. It can be processed like wood sleeper, such as grooving, drilling, sawing, etc. In case of damage to the rail spike hole, the special adhesive can be poured after the rail spike is taken out, and then the rail spike can be drilled and screwed in, without affecting the pull-out resistance of the rail spike.

 

  • 4000m deep sea smart buoy pressure resistant shell - Harbin FRP Institute Co., Ltd.

4000m deep sea smart buoy pressure resistant shell - Harbin FRP Institute Co., Ltd.
This product is expected to be used as the carrier of deep-sea environmental detection equipment that placed in the marine environment for networking for data collection of sea water temperature, salinity and current change in observation waters and can adjust its position, receive instructions or return data according to the needs. Production Place: Harbin, Heilongjiang Province, China.

Innovation points:

1. Structure design of multi section series connection of composite pressure resistant shell.

2. Integral waterproof sealing technology of composite pressure resistant shell.

3. Optimizing of sealing function of cylinder internodes within finite space.

 

Part 3 - PROCESS & EQUIPMENT

  • 5-axis milling and additive manufacturing integrated machine (BGAM) - Shanghai Coin Robotics Technology Co., Ltd.

5-axis milling and additive manufacturing integrated machine (BGAM) - Shanghai Coin Robotics Technology Co., Ltd.
BGAM is widely used in the production of large to very large parts, molds, models and industrial tools made of reinforced thermoplastic materials. Application includes aerospace, rail transportation, wind power, yacht and landscape and other composite materials. Production Place: Shanghai, China.

Innovation points:

1. BGAM adopts the double gantry structure innovatively, which can be used for both 3D printing and five-axis processing to achieve  additive manufacturing and subtractive processing; Through additive manufacturing to print out workpieces that are close to the final size and contour, and then reach the final through milling The size, the material removed is much less, the processing speed is faster, the cost  is lower, and the material use efficiency is higher.

2. BGAM has large working space, the standard working space can reach 6m*3m*2m, and the larger working space can reach  10m*6m*3m, which is specially designed for printing and processing of large and very large workpieces. The size is the largest size of similar equipment in China.

3. Under the premise of ensuring the stability and accuracy of the gantry (0.015mm/1000mm), the high-speed printing gantry can reach 50m/min at the fastest, and it is equipped with a large flow 3D print head to achieve efficient printing and perfectly reflect the geometric grade of additive manufacturing efficiency advantages.

4. The high-flow 3D printing head with CoinRobotics' revolutionary technology, which is specially designed for pellets, has multiple temperature control processes to ensure better composite processing results and achieve extremely high melt quality. And it can support a maximum processing temperature of 400°C and a variety of fiber composite thermoplastic polymer materials. It is equipped with K10 (10kg/h) extrusion head as standard, and K20 (20kg/h) and K50 (50kg/h) extrusion heads can be selected.

5. Break through the traditional large-scale composite material mold manufacturing process (such as wind power blade molds, yacht molds), and can directly print the female mold without the need for a plug. The degree of automation is higher and the efficiency is greatly improved.

6. BGAM supports a variety of fiber composite thermoplastic polymer materias. CoinRobotics has mature application experience of ASA-GF glass fiber composite material and ABS-CF carbon composite particle. ASA, ABS plastics have been widely used in machinery, electrical, textile, automotive, aircraft, shipbuilding and other manufacturing industries and chemicals. In terms of performance,  considering the high mechanical strength and high temperature resistance of materials required for part / mould processing, we have composited glass or carbon fiber in the base material, which can effectively improve the mechanical and thermal properties of the material. In terms of printability, the thermal expansion coefficient of the material is effectively reduced, the interlayer adhesion is improved, and the warpage during printing is suppressed, while the finished product is given better dimensional stability. In terms of cost, the cost of pellets is even lower, only one-tenth that of traditional FDM wire.

7. Invented patented material compaction technology, up to dozens of tapping frequencies per second, makes the bonding between printing layers more reliable. The self-cooling and anti-sticking technology of the clapper prevents the melt from sticking to the surface of the clapper during the tapping process, ensuring the molding effect.

8. For the manufacture of large-scale architectural landscapes, non-linear complex curved surface modeling can be realized, and the designer's creative ideas can be realized.

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