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JEC-CCE Innovation Awards 2015

News International-French

2 Sep 2015

The jury for JEC Group & Composite China Expo 2015’s Innovation Awards took place on September 1st 2015, awarding ten prizes to the best projects in various industries.

 

 

 

 

Category: Raw Materials

Winner: Tiance Technology Co., Ltd.


Modified Bismaleimide Resin with Low HDT and High Thermal Resistance

Applications:

- Aeronautics and Astronautics: wing stabilizer spars, fuselage skins and stiffeners, engine components and critical load-bearing components

- Microelectrics: advanced copper clad laminate

- Chemical: heat-resistant adhesive

- Other fields requiring high thermal resistance and high load

 

Technical Features

The modified bismaleimide resin in this paper was prepared by adding a novel modifier with innovative properties. With the optimization of the synthesis process and formulation design, the resulted modified bismaleimide resin was sticky glue or even liquid at room temperature. At present, the disadvantages of the common bismaleimide resin were obvious. The HDT was too high (over 80°C generally), the stability poor (sometimes the component could depart from the resin), the thermal resistance not good enough and the cured system was fragile. The modified bismaleimide resin, however, solved these problems successfully:

- The HDT was lower than room temperature and the viscosity at process temperature was low enough( - The resin was of good stability. Room temperature storage was up to 90 days.
- The adhesion of the prepreg was sufficient.
- The thermal resistance of cured resin was excellent. Tg>330°C, Td>400°C.
- The mechanical performance was favorable. The flexural modulus was 15% higher than XU292 (a kind of common bismaleimide resin from Ciba-Geigy).

In summary, the modified bismaleimide resin improves its heat-retardant and mechanical performances, as well as optimizes its processibility. It can be used to produce prepregs by using the melting method, and is well suitable for such processes as RTM, filament winding at temperature as low as room temperature. The synthesis process does not produce any pollution and can be completed in easy conditions, which ensures the stability of the products.


Market

 

At present, the modified maleimide resin has been provided to AVIC and CASC as well as many other scientific research institutions or high-tech enterprises and has thus far received good feedbacks. The resin has obtained general recognition from the market. In the future, the resin will be further developed to have higher strength, higher toughness, lower cost and liquid family member, thus winning bigger market expectation and economic benefits.

 

Category: Raw Materials

Winner: Chongqing Polycomp International Corp.

 

TM+ New Generation Fiberglass

Applications:

Wind blades and other high-performance fields.

 

Technical Features

Weaving Processability: CPIC Research & Development Center had previously developed the sizing for TM+ fiberglass that specifically targeted wind energy applications. By fully considering the utilization characteristics of weaving, TM+ has the advantage of low fuzz, quick wet-out and high interfacial strength. The company optimized the sizing and manufacturing techniques against the slough-off and tie-off issue, improving the weaving efficiency.

GRP mechanical properties: Thanks to an optimized glass formulation design, a world-leading fiber-drawing technique and sizing, TM+ fiberglass has excellent GRP mechanical properties. The modulus and strength of the composite sheet made of TM+ are separately 2.5% and 8% higher than other market-oriented high strength high modulus products. The improvement of material property lays a good foundation for elongation and wind blades weight-loss.

Outstanding fatigue performance: The product development focuses on the fatigue performance for meeting the needs of wind energy applications. After practice and assessment for over one year, it has been confirmed that the sizing formulation of TM+ is the most optimal one selected from more than 100 formulations.

Environmental benefit: Boron-free and Fluoride-free, the whole production process avoids the emissions of harmful substances.

 

Market

In response to the call of the national energy conservation and emissions reduction, CPIC developed the new generation TM+ to support wind energy applications by helping reducing the blade’s weight and lengthening the blade. TM+ fiberglass can improve the bolt fatigue life significantly and meets the demand of larger blades.

 

Category: Raw Materials

Winner: Zhongfu Shenying Carbon Fiber CO., Ltd.


SYT55 Carbon Fiber With High-Strength And an Intermediate Modulus

Application:

SYT55 carbon fiber has high tensile strength, an intermediate E-Modulus and better break elongation. It can meet the requirements of light-weight and higher stiffness for composite structures and be used for primary load-carrying structure of passenger aircraft, aerospace grade pressure vessel and other civil field with higher requirement of stiffness for structures: such as bike, fishing poles, high precision robotic arm.

 

Technical Features

Zhongfu Shenying innovatively use a polyacrylonitrile precursor made with a dry-jet wet spinning process to produce a high performance carbon fiber with high strength and intermediate modulus. The dry-jet wet spinning process technology ensures a soft, compact surface as well as obtaining double-diffusion and solid-liquid phase separation in the coagulation bath. The fiber surface is smooth with limited defects. The speed rate can reach up to 350m/min, which is four times higher compared to the wet spun process. Through a process technology of fine denier precursor, homogeneous structure and higher graphitization, Zhongfu Shenying succeeded in producing high performance carbon fibers with high strength and intermediate modulus on a large-scale. The main features of the SYT55 carbon fiber are less fuzzing and higher fiber strength conversion.

SYT55 carbon fiber had been tested by Beijing University of Chemical Technology (BUCT), Beijing University of Aeronautics and Astronautics (BUAA) and other authoritative inspection organizations of carbon fiber and carbon fiber composites. The testing results from BUCT is as following: tensile strength is 6002Mpa, modulus is 296Gpa, break elongation is 2.03% and liner density is 441 g/km.

 

Market

The need of carbon fiber with high tensile strength, intermediate E-Modulus, especially carbon fiber made by dry-jet wet spinning, has become increasingly great with the rapid development of civil aircraft, downstream defense industry in China. The market demand is huge in the sport & leisure field, precision machinery and other civil products that have higher requirements on tensile strength, light-weight, higher stiffness and degree of comfort, carbon fiber with high tensile strength.

 

Category: New Applications

Winner: Ningbo Institute of Material Technology & Engineering, Chinese Academy of Sciences
Partner: Chery Automobile Co., Ltd.

 

Continuous Carbon Fiber Reinforced Polyphenylene Sulfide(CF/PPS) Front Bumper

Applications:

This project, consisting in a lightweight structure technology for car bodies, is one of the most effective ways for energy saving and improved driving performance. The front bumper is a typical structural part for the application of composites in vehicles. The product of a continuous carbon fiber reinforced polyphenylene sulfide composite front bumper can be used for cars with a monocoque body or body chassis frame construction. The manufacturing process can also be extended to fabricate other types of automotive panels and be applied in other fields.

 

Technical Features

 

 

High performance continuous carbon fiber reinforced thermoplastic composites have been widely used in aerospace, navigation, national defense, automotive, civil engineering and other fields due to their excellent properties. However, the manufacturing efficiency of continuous fiber composites has always been a difficult problem. This product has shown that the low-cost and automatic manufacturing technology of continuous fiber reinforced thermoplastic composites is possible. It contains three processes: hot-melt impregnation, continuous laminate preparation and hot stamping. The production efficiency can reach 8 parts / hour, which satisfies the demand of mass-production for vehicle structure parts with high mechanical properties in automotive industry.

 

Market

 

 

With the challenges of safety, energy saving and environmental protection in the global automotive industry, electric car technologies play a strategic part in dramatically reducing the energetic and environmental burdens. Thermoplastic composite constructions open up great potential in electric cars for weight reduction, which have been growing steadily. This is the case especially in automotive and aerospace applications, due to their recyclability, improved impact resistance and rapid processing ability. At present, discontinuous fiber-reinforced thermoplastic composites have been widely used to manufacture secondary structure parts in the automotive industry, while primary structure parts have an increasing demand for continuous fiber-reinforced thermoplastic composites to meet the requirements for high mechanical properties. The continuous carbon fiber reinforced polyphenylene sulfide composite front bumper can be fabricated at a mass production rate, which overcomes limitations of manufacturing and cost associated with traditional continuous fiber-reinforced composites. It shows great potential in industrial applications and will further promote the development of new markets for composite in the range of tens of billions of RMB.

 

Category: New Applications

Winner: Harbin FRP Institute

 

Rocket Engine Bracket Made of Carbon Fibre Composite


Applications:

Carrying assistant flight engines of all angles.

 

 Technical Features

The carbon fiber bracket developed for the Shanghai Space Dynamic Institute was made with carbon fiber instead of metal for the first time in China. Its weight decreases by a third compared with metal brackets. The technologies are quite different: for the carbon fiber bracket, in-mold technology is adopted to highly increase the product performance. The problem of the strength and stiffness design and check was solved through analyzing and optimizing the complex multi-opening structure accurately in the finite-element method. There are no other reports of similar products in China.

 

Market

The product created great economic efficiency and market prospect. The invention of the product had vast importance to the domestic space flight area. The successful development of the product obtained the recognition of the users. Later we continued researching and developing more types of composite brackets. The brackets carrying all the small engines of Chang’e-3 successfully were made bythe Harbin FRP Institute. These years’ developing experiences will offer powerful support for the use of the composite bracket instead of the metal bracket in future.


 

Category: New Applications

Winner: Wuhan University of Technology, China Harzone Industry Corp., Ltd


Fast-Erecting Modular All-Composite Heavy-Duty Emergency Bridge

Applications:

The emergency bridge can be used over waters, with a maximum load of 40 tons. It is composed of different lightweight modulars, easy for transportation and installation. By doing so, the overall weight is reduced by 20%, compared with traditional steel bridges.

 

Technical Features

Traditional emergency bridges are made of steel and aluminum alloys, connected by welding or bolting. But their heavyweight can no longer satisfy markets requirement for lighter structures. As a better alternative, composites can greatly reduce the bridge’s weight, shorten the installation time while fully fulfilling the requirements for 40 tons loading capabilities.

The heavy-duty bridge is 8m in length, composed of 12 modulars or 6 units. Each modular spans 4 meters. The bridge is wholly composites-made, with maximum load capacity of 40 tons. Horizontally, Units are connected with each other horizontally by self-locking structure and each unit is produced using VA-RTM process. Vertically, modulars are connected with each other by a connector, made with uni-directional carbon fiber and metal ear. Each ear can bear a maximum loads of 17 tons while each unit has 5 metal ears, which makes it can bear 85 tons loading. The single modular weight is inferior to 140Kg. The span is of 7.5m, the center deflection is inferior to 90mm under 42 tons static load and it has passed 43 tons wheel tests (500 times) and 40 tons track tests (200 times), with no failure.

 

Market

 

Composites emergency bridges have been studied and developed for many year in developed countries because of their very interesting properties. China is a country with regularly occurring natural disasters, where composites emergency bridges are expected to have a huge market potential. This product may be well applied in Defense Industry, Disaster Relief, Engineering Construction, etc.

 

Category: New Applications

Winner: Beijing Sinoma Composite Auto Parts Co., Ltd.
Partner: Hollow Composites Division of Sinoma Science and Technology Co., Ltd.


High Performance, Low Loss, and Overall Forming Hollow Structure Radome Body

Applications:

This project could effectively increase the wave performances of antenna systems. This radome is mainly used in aerospace, communications vehicles, weather radars and mobile base stations.

 

Technical Features

The overall forming hollow radome body is a new type of wave-transparent concept, with a performance that is turning out to be better than traditional honeycomb and foam structures. The hollow radome body has the following properites: high strength, delamination resistance, high pressure resistance, leakage resistance, corrosion resistance, anti-aging, easy forming, wave-transparent well, low cost, etc., Existing antenna protection devices usually put forward higher requirements in wave-transparent, strength, aging performance and so on, but currently the electric performance is poor (dielectric constant is 3.8-4.2, loss tangent value is greater than 0.009) and the overall molding hollow of the radome body wave-transparent performance is better (dielectric constant is 1.8-2.5, loss tangent value is less than 0.007). During the development of the overall forming hollow antenna radome process, the company developed a dedicated presoaked cloth, achieved the hood body continuous molding technology, and carried out the performance study and the design and evaluation of structural strength.

 

Market

At present, Beijing SInoma Composite Auto Parts has carried out the development of the aviation and aerospace broadband radome of the overall molding hollow radome body. Product performance and structural strength have significantly increased compared with cellular or foam structures. In addition, with the development of 4G/5G technology, there is an appeal to upgrade the low loss, broadband radome body. The market demand is expected to reach 400,000 pieces per year, and has good market application prospects.

 

Category: New Applications

Winner: Sinoma Science & Technology (Suzhou) Co., Ltd.


Composite Jumbo Tube

Applications:

This product is mainly used for storage and transportation of compressed natural gas.

 

Technical Features

 

 

This large-diameter composite tube unit distinguishes itself by presenting a lower cost, advanced and integrated technologies and a shorter development cycle compared to similar products. “Sinoma” is a manufacturer engaged in rapid and large-scale production and has optimized comprehensive performances.

 

The tube unit consists of a carbon fiber composites body, electrochemical corrosion-resistance coating, insulation structure, as well as a cracking resistance structure. These specifications can satisfy the storage and transportation requirements of the gas industry. The product meets the international ISO 11515 standard. The volume-weight ratio of a large-diameter composite tube is at least 30% higher than a traditional steel tube, allowing, for a same weight to transport more gases. As a storage and transportation method, large-diameter composite tubes provide a new solution for the natural gas industry, contributing to increase transportation efficiency and decrease costs, thus having a good market prospect. This product contains four key technologies:

- High strength and light weight composite layer design

- Fatigue and cracking resistant structure for composite layer

- Electrochemical resistant corrosion coating and insulation structure

- Multiple tubes assembling and fixing technology

 

Market

 

 The product has drawn attentions from clients home and abroad and won quite a new oversea orders. Due to its lightweight and large volume, the market potential is huge.

 

Category: New Applications

Winner: Changzhou Hongfa Zongheng Advanced Material Technology Co., Ltd.
Partners: Changzhou Greenauto Union Co., Ltd., Beijing University of Aeronautics and Astronautics


Lightweight-Module and High-Performance Composite Bus

Applications:

The product has excellent properties, such as low noise, thermal insulation and heat insulation. It can save energy, reduce environmental pollution, ensure safety as well as reducing rolling resistance.

 

Technical Features

 

Technology: Thanks to its lightweight composite body structure -different from traditional structures in which the bus body and chassis were welded, the bus is much lither and presents better mechanical properties. It also makes it possible to create different types of buses depending on the users’ requirements.

Performance: The bus body and inner and outer panels use both thermoplastic and thermoset composites sandwich structures. Thanks to this set up, not only does it ensure the bus body’s strength, stiffness and impact properties, but also sharply reduces its weight.

Process: A high voltage RTM manufacturing process is used for the process of the body parts. Compared to traditional RTM process, it reduces the resin injection time, improves the quality of impregnation, and shortens the molding cycle. The product has the following characteristics: (1) high production efficiency; (2) a highly automated process;(3) shorter processing cycle;(4) no need to use auxiliary materials both in preprocessing and injection process;(5) good surface quality and low porosity.

Environment: The main power source of the product is batteries. In terms of energy conversion, electric energy is cleaner than burning fuel directly.

 

Market

 

The automotive industry is the national economy’s pillar and has achieved rapid development in recent years. This has led to the rapid increase of car ownership, but also brings three major problems: lack of energy, environmental pollution, and safety problems. Reducing fuel consumption and pollution to the environment have become key problems of the auto industry development need to be resolved.

 

Category: Process & Equipment

Winner: Taizhou Europ Mould & Plastic Co., Ltd.


Highly Efficient Double Workstation RTM Press & Molding Technology

Applications:

This system can be widely used to mold different types of fiber reinforced products. It's a new technology combined with HP-RTM, Vacuum RTM and SMC molding advantages. So far, Taizhou Europ Mould & Plastic Co is the only company in the world who is widely applying this technology. Its advantages are as follows:

- Strong & hard steel mould with A-Class surface, which can ensure accuracy & stable sizes
- 2 to 4 times higher efficiency than current molding technology.
- The product performances rely upon machines rather than workers, which allows a more stable production of high-quality products, as well as reduces labor costs.

 

Technical Features

This technology observes one fixed upper mould, with two other moulds beneath taking shift in turns. When one is injected and cured, the other can be cleaned and the gelcoat and fiber mat can be placed in. It greatly enhances the working efficiency and shortens the production cycle to 30mn. It is heated with water to ensure stable temperature and furthermore stable product performances. What’s more, it has a fast vacuum system and the valve can pump air out as fast as 10-20 seconds to save time. The resin filling (10 bars) and molding pressure are much higher than for Vacuum RTM. Considering the previous advantages, the products made from this new technology are much better and cheaper than hand lay-up and Vacuum RTM.

More information: www.chinacompositesexpo.comwww.jeccomposites.com

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