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JEC Composites is announcing the new winners of the JEC Asia Innovation Awards Programme 2010. This year, 9 companies and their 16 partners will receive awards at the JEC Asia Composites Show (October 12-13-14, 2010 Singapore).
(Published on October 2010 - JEC Magazine #60)
The programme was created in 1998 with the goal of promoting innovation. “Through this programme, the JEC Group projects and promotes successful innovation strategies onto the international scene throughout the year”, explains Frédérique Mutel, JEC President and CEO.
This top-level competition for Innovation is a focus of attention in the international composite market. It is supported by major companies and trade magazines in the industry that are committed to the development of composite innovation. Each year, a jury of renowned international experts chooses the best composite innovations, based on their technical interest, market potential, partnership, financial impact and originality. The 2010 jury is composed of 16 international composite experts: Alan Chen (General Manager, Topkey Corporation - Taïwan), Steven Cheng (Vice President, En- Liang Enterprise Co., Ldt – Taïwan), Ebrahim Ghavamshahidi (Technical Director, Umeco Composites - United Kingdom), Peizhi Gu (Senior Consultant, China Com- JEC Asia Innovation Awards Programme 2010 30 jec composites magazine / No60 October 2010 posites Group Corp - China), Fukuda Minoru (Executive Officer and General Manager Kurimoto Ltd, Plastics Product Division - Japan), Professor K. Munshi (Indian Institute of Technology - Industrial Design Centre Mumbai - India), Frédérique Mutel (President and CEO, JEC Group – France), Kanemasa Nomaguchi (Board Member, JRPS International Exchanging Committee - Japan), Philippe Odouard (Chief Executive Officer and Managing Director, Quickstep – Australia), Hariharan PV’s (Chief Mentor and Promoter, Agro-Biogenics - India), R Raman (Managing Director, Modern Engineering Plastics Pvt. Ltd MEPPL – India), Murray Scott (Managing Director of ACS Australia and CEO of CRC-ACS Composites - Australia), Dr. A.Selvam (Executive Secretary, FRP Institute - India), Ravi Shrivastava (General Manager of Marketing and Projects, Kineco Pvt. Ltd - India), and Jung Seok Kim (Principal Researcher, Korea Railroad Research Institute - Korea) and Tong-Earn Tay National University of Singapore.
Since the last past 5 years, UMECO Composites (Official Partner) has been actively supporting the JEC Innovation Awards competition.
These awards have also been supported by many prestigious companies such as Huntsman Advanced Materials (Platinum sponsor) and also C.A. Litzler, Cray Valley, Cytec Engineered Materials, Diatex, Dow, DSM Composite Resins, Hexcel, Menzolit, Nanoledge, Owens Corning OCV Reinforcements, Polynt SpA, RocTool, Soficar – Groupe Toray, SGL Group, Ticona, Vestas and Virtek Aerospace.
This year, the winners were selected from the following categories: Environmental Raw Materials, Advanced Raw Materials, Process, Aerospace, Automotive, Building and Construction, Electrical and Electronics Engineering (EEE), Mass Transportation and Pipes. The decision to give prominence to these projects was based on their atypical nature and various noteworthy aspects.
Winner: Rhodia (China)
Partner: DSM Euroresins (Switzerland)
Environment-friendly solvents for composite manufacturing
Rhodiasolv is a solvent synthesized from a by-product of polyamide 6-6 synthesis. It is protected by several patents. This diester molecule with no risk phrase can replace dangerous solvents like ketones, chlorinated solvents, NMP, or isophorone. It has a low volatility, very good solvent properties, and is ecofriendly and non flammable. Rhodiasolv is indicated for dissolving polyesters, epoxy and polyurethanes in place of dichloromethane, NMP or acetone.
The development started in 2005. The synthesis process development, registration and tox/ecotox studies took place in 2007. In 2008, patents were published, formulated products were developed for various applications and a life-cycle analysis was performed. In 2009, the sales development process was ramped up with partners and key market customers.
Several hundred tons were produced. Sales and an industrial production unit are being developed in 2010. The need to replace toxic and volatile solvents is growing continuously.
The potential for the composite market alone is estimated at several tens of thousands of tons over the next 10 years.
Winner: Jushi Group Co.Ltd (China)
Partner: Flexpipe Systems (Canada)
High Performance glass fibres for HDPE composite pipes
High-performance glass fibre E6DR-735- 386T is an E6TM glass with special corrosion resistance and high strength, a special sizing treatment and filament drawing process. It was developed to reinforce HDPE in the manufacture of composite pipes.
The development process started in March 2009 and lasted more than a year. Samples were provided to customer Flexpipe in September 2009. Flexpipe and other customers have now completely accepted the product.
Winner: Coatema Coating Machinery GmbH (Germany)
Partner: Forschungszentrum Juelich (Germany) and Technical Research Centre of Finland (VTT)
Click and Coat technology
Current pilot and production coating line concepts for coating of paper, textiles or films are fixed solutions. Coatema’s new Click&Coat technology features a highly adaptable and flexible concept combining different production procedures in the area of coating, printing and laminating. Click&Coat offers not only the vast flexibility of different coating technologies, but also numerous plant layouts and process sequences. The basic idea is to use standard modules, assembled together to rapidly create a specific production unit. This concept is very useful for research centres and companies that frequently change their production.
The individual components and aggregates are movable and can be connected via a user-friendly yet very effective connector system, which is designed for perfect arrangement of all aggregates in the desired position. Furthermore, it ensures a direct connection to the electronic steering and software system.
The Click&Coat technology can be used very easily and simply in different processes. Each of the 40 different units comes with its own switch cabinet, and the innovative design eliminates many electrical and steering cable connections: both the entire plant connection and the process steering are ensured by a single electrical connection in between. Each unit is equipped with adjustable wheels to be moved into different process positions. The units are connected and fixed using the Click&Coat mechanism.
This flexibility gives a maximum of process variants with the different components concerning coating, drying, curing or IR or UV cross linking, as well as other process technologies. When combined with Coatema’s modular, changeable coating systems for coating and printing processes, this technology makes it possible to react to technological changes very easily.
As regards the composite market, the first line is currently being installed. It will be capable of implementing 5 different coating methods for direct or indirect coating on paper, rovings and other typical composite substrates.
Winner: Henkel (USA)
Partner: Alenia Aeronautica S.p.A (Italy), Diamond Aircraft Industries Inc. (Canada)
Film adhesive and adhesive paste for out-of-autoclave processes
The autoclave processing of bonded parts has been, and remains, an expensive route to the assembly of composite structures. Large, expensive pressure vessels, highstrength tooling and special adhesives are required to successfully make a part.
Companies are eliminating the autoclave process to cut overall costs.
Raw materials, especially resins and adhesives, need to be reformulated to maintain the performance of composite parts. The Hysol® PL 696 film adhesive meets the requirements for out-of-autoclave processing. Foam elimination during the vacuum bag cure of film adhesives was achieved by formulating and processing changes that avoid the foam generation mechanism
Structural adhesive performance at large bond thicknesses was preserved through the development of the Hysol® EA 9380 paste adhesive, which is uniquely formulated to maintain the required properties. With Hysol® PL 696 and Hysol® EA 9380, the autoclave can be removed from the processing scheme, which reduces the overall cost of composite structures.
Products are now available for production.
Winner: DLR German Aerospace Center – Institute of Vehicle Concepts (Germany)
Partner: ACE Advanced Composite Engineering GmbH (Germany)
Ribs and space frame unit for cars
The rib and space frame unit is made up of three ribs (replacing the former A, B and C pillars) connected with metal longitudinal rails and castings. The simple geometry of the metal profiles compensates for the higher cost of the CFRP parts and allows a variable vehicle design (length). Within the new vehicle structure, the B rib is one of the most stressed parts in case of a side impact. The DLR’s goal was to create a structure combining outstanding performance and lightweight design for the B rib. The circular design itself offers the advantage of withstanding high radial loads (side impact). This geometry was combined with carbon fibres and the corresponding part design fulfilled both requirements.
Each segment of the B rib has to carry out different functions. The lateral part must be very stiff to form the passenger compartment. Topology optimizations were performed to find the best cross section. In case of an accident, the upper part of the B rib works as a hinge. The lateral part rotates around this hinge and the crash energy can be absorbed by the lowest section of the B rib. The greatest deformations occur under the passenger seat, at a place where they have fewer implications for the passengers’ health or life. This guarantees a high level of safety within the passenger compartment.
The loads on alternative power systems can also be reduced. Hence, the possible indirect dangers caused by highvoltage batteries or hydrogen tanks below the passenger compartment are reduced.
The value created by the use of fibrereinforced plastics, CFRP here, results in a high safety level while reducing the weight of the part and its adjacent components (about 35% compared to the reference structure).
The aim of the current development is to prepare the B rib for the American sideimpact test according to IIHS, which is currently the most demanding one.
Because many car manufacturers currently face similar challenges (how to integrate CFRP into the body of the vehicle), the DLR Institute of Vehicle Concepts has a good chance of transferring this know-how into automotive applications.
Winner: DK Composites Sdn. Bhd. (Malaysia)
Partner: Gurit (Australia)
Manufacture, installation and cladding of the Lotus-shaped structure of the Arts and Science Museum in Marina Bay waterfront (Singapore)
The structure, measuring 12,500 m2, is supported by 2,900 m2 of stainless steel and 1,300 m2 of aluminum composite mega column, making it one of Southeast Asia's most prominent architectural and engineering feats:
There was no past precedence from other projects in the world for such a large structure. The project is amongst the largest free standing composite structures in the world today.
The value is speed of installation, light structure, and a completely monolithic surface which is not possible with any other cladding material. When completed the aesthetic value of this building is “ immeasurable “ and probably the first of its kind ever accomplished in composites.
The job was won by DK by international tender and with a 12 month completion period ended July 2010.
Winner: Fuji Resin Co. Ltd. (Japan)
Partner: Mitsubishi Heavy Industries (Japan), Toshiba (Japan) and Hitachi (Japan)
Sophisticated anti-corrosion technologies using a very special composite system
Chemical-resistant thermosetting resins such as vinylester, phenolic and epoxy resins are used with glass fibres, glass flakes and fillers as raw materials. A special processing technology is applied with unique know-how.
The composite lining replaces other materials like lead (heavy metal) or glass (brittle).
The composite solution has a very long life and is highly corrosion- and abrasion-resistant. For example, Fuji Resin’s composite product, Fuji Chemeq 10 (phenolic resin and high chemical resistant grade fiber) has excellent resistance (i.e. 20 % Hydrochloric Acid ((HCl)) at 110° c or 70% Sulfric Acid (H2SO4) at 110°c. Pipes and pipe-type equipments applied with Fuji Chemeq 10. Mitsubishi Heavy Industries Co are a big end-users of these pipes.
In production for many years. High number of industrial references, particularly in energy.
Winner: Huntsman Advanced Materials (China)
Partner: Holst Center (Netherlands) and Groupe Oreca (France)
OLED lighting included in composite parts
The rear mirror of the Oreca Le Mans racing car uses a carbon composite material that incorporates a low-energy- consumption lighting functionality based on a revolutionary lighting device called OLED (organic lightemitting diode).
OLEDs are paper-thin, flexible and lightweight devices that consume up to 70% less energy than conventional light sources, making them prime candidates for the next generation of lighting.
A thin, flexible barrier coating was developed by Huntsman Advanced Materials and then successfully processed by the Holst Centre, which then produced the final OLEDS. The film’s barrier properties provide an unprecedented level of protection.
In measurement of the flow of water through the film, the water vapour transmission rate (WVTR) coefficient is close to 10-6 g/day/m² for an ultra-thin layer of materials (about 30-40 μm barrier layer thickness representing only some 40-50 g of coating material).
A one-shot process to integrate the final flexible OLEDS into the composite structures was developed by Huntsman Advanced Materials and then applied by Oreca’s specialists to the manufacture of the rear mirrors. The OLEDS can be integrated, bonded and protected through different standard processes (infusion, RTM, prepreg…). The prepreg process was qualified for the Oreca mirrors.
OLEDS constitute a more efficient and brighter lighting solution than standard ones. The Oreca Rear mirror demonstrates the possibility to incorporate a low-energy-consumption lighting functionality into composite structures without increasing weight.
The joint collaboration between Huntsman and the Holst Centre for the development of high barrier coatings for OLEDS, in the frame of the “Fast-2- Light” EU-funded project started in 2007. In june 2010, rear mirrors were used during 24h Le Mans race.
This will bring value in future applications, for instance in mass transportation, design, architecture, signage, etc.
Winner: Hankuk Fiber Co. Ltd. (Korea)
Partner: ADS Rail Co. Ltd., (Korea), Dongil Transportation Co. Ltd., (Korea) and various divisions within the Hankuk Group (Korea)
Hankuk Fiber's innovation is mass production of CNG Low Floor Buses with a composite car body for Korea domestic market.
The manufacturing process of composite car body consists of the following steps: preparation, lamination, curing, demoulding and processing.
A resin-coated glass-fibre fabric, AL H/C and reinforced structures are used as raw materials. Considering workability, the car body can be divided into a main car body sections, various covers, a chassis centre structure and partitions. The fact that the electromagnetic shielding and electrical properties of glass fibre-reinforced composite materials are sometimes lower than those of existing steel car bodies was also considered during the design step.
A composite car body provides many advantages compared with existing steel car bodies, including an aesthetically pleasing, streamlined design.
Mass production of the bus started in November 2009, following a 38-month study phase and approximately 12 months of testing/certification under the supervision of the South Korean Minister of Land, Transport and Maritime Affairs (MLTM).
There is a large worldwide market potential for this kind of bus. In this market situation, the composite car body reduces CO2 emissions and also user costs through weight saving.
The use of CNG-powered buses has been spreading steadily since the early 1990s.Hankuk is the only manufacturer of low-floor CNG buses in South Korea that applies composite materials to a whole bus body.
Dongil Transportation is the first customer who purchased our 5units of CNG Low Floor Buses on Nov. 25th in 2009.