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03 Aug 2009

JEC Asia Innovation Awards 2009

JEC Composites is announcing the new winners of the JEC Asia Innovation Awards Programme 2009. This year, 9 companies and their 15 partners will receive awards at the JEC Asia Composites Show (October 14-15-16, 2009 Singapore). 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 2009 jury is composed of 13 international composite experts: Alan Chen -Topkey Corporation (Taïwan), Ebrahim Ghavamshahidi (Umeco Composites - United Kingdom), Peizhi Gu (China Composites Group Corp - China), Frédérique Mutel (JEC Group – France), Kanemasa Nomaguchi (JRPS International Exchanging Committee - Japan), Hariharan PV’s (Agro-Biogenics - India), Murray Scott (CRC Composites - Australia), Dr. A.Selvam (FRP Institute - India), Henry Shan (Cell Power Co., Ltd - Taïwan), Ravi Shrivastava (Kineco Pvt. Ltd - India), Narasimalu Srikanth (Vestas - Singapore), Tong-Earn Tay (National University of Singapore - Singapore) and Jung Seok Kim (Korea Railroad Research Institute - Korea).

Since the last past 4 years, UMECO Composites (Official Partner) has been actively supporting the JEC Innovation Awards competition: “We work very closely with JEC and we have been supporting the JEC Innovation Awards for the last four years, not only in Europe but also in Asia. The industry has built its success on technical innovation and JEC is doing a fantastic job in promoting innovation for the industry; This is a great opportunity for engineers throughout the industry to collaborate and to gain recognition for the new ideas that they are promoting in terms of solutions for technical and commercial issues. We are very pleased to be an active supporter of these Innovation awards. “. Andrew MOSS, Chief Executive, Advanced Composites Group.

These awards have also been supported by many prestigious companies such as C.A. Litzler, Cray Valley, Cytec Engineered Materials, Diatex, Dow, DSM Composite Resins, Hexcel, Huntsman Advanced Materials, 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: Environment and Recycling, Raw Materials, Process, Automation, Aerospace, Building and Construction, Sports and Leisure and Transportation. The decision to give prominence to these projects was based on their atypical nature and various noteworthy aspects. Read through the trade description to discover the 9 winners. The 2009 JEC Awards ceremony will take place on Wednesday October 14th at 5:00 pm on the JEC Show and will be open to all visitors (free access).



Category: Environment & Recycling
A brand new environment-friendly surfboard, using renewable cellulose reinforcements

Winner: Cobra International Co., Ltd. (Thaïland)
Partner: Porcher Industries (France)

Cobra international launches a brand new environment-friendly surfboard, using renewable Greenlite reinforcements developed by Porcher Industries. In this application, standard glass-fibre reinforcement is replaced with Greenlite material, a new generation of high-performance renewable reinforcement. The parts concerned are surfboards, windsurf boards, kite boards and wake boards. Greenlite uses pure cellulose fibres to replace glass fibres.The new material constitutes a significant advance, since the other bio-based solutions considered did not offer the required quality, reproducibility and strength.

Greenlite material is biodegradable and highly compatible with bio-based resins, making it suitable for the production of 100%-bio-based composites on a large scale. Greenlite reinforcements are already available in various styles at the industrial scale for a wide range of composite applications, including summer and winter boards.
The new material is processed using standard equipment, with no modification of the existing technology. The new reinforcement has a unique whiteness and a positive effect on final part surface quality, thus improving aspect and minimizing subsequent rework. The final surfboards offer excellent
surface finish, no weight increase, and very good performance. The first surfboards made of Greenlite fabrics kindled considerable enthusiasm and excitement among surfers.

Other finalists in the Environment & Recycling category:
• Rapid sun-light UV-curable prepregs presented by Australian Composites Pty Ltd. (Australia) with its partners LM GlasFibre (Denmark) and Cooperative Research Centre for Advanced Composite Structures Limited.
• Continuous pyrolysis process for the recovery of carbon fibre from carbon-fibre-reinforced composites presented by Recycled Carbon Fibre Limited (United Kingdom) with its partner the Boeing company.
• A ‘green floating' house. A full concept for living on water on a foundation of recycled waste (Polystyreen/RexwallTM), presented by Studio Noach (United Kingdom).



Category: Raw Materials
A ground-breaking material endowing composites with high fire-resistant properties

Winner: Regina Glass Fibre Pty Ltd. (Australia)
Partners: CRC-ACS (Australia) and Ampelite (Australia)

FireShield® is a chemically loaded surface tissue that can be added to any composite laminate during manufacture to provide fire-resistance. Using this product as a normal surface tissue, the manufacturer produces a fire-resistant laminate. When FireShield® is used as the exterior ply in a composite laminate, the halogen-free fire-retardant chemical is placed just beneath the surface, where it is most needed. This approach to providing fire resistance does not require any special fire-retardant resins, and thus allows standard laminating resins to be used to manufacture composites that meet international fire standards. When exposed to flame, FireShield® produces a well-bonded charred layer on the surface of the product.

This insulates the product and inhibits the passage of oxygen, thereby smothering the flame. Furthermore, the environmental problems caused by the use of halogenated systems are avoided. The use of standard resins means that laminate manufacture is straightforward, material costs are lower, and there is no compromise in the strength or stiffness of the composite laminate. Although non-woven glass tissue provides the lowest-cost fabric for the FireShield® technology, carrier fabrics of other fibres such as polyester or carbon, either woven or non-woven, can be used to meet specific engineering design requirements.

Manufacturers do not need to modify processes or train staff in order to produce composite structures that meet international standards for flame, smoke and toxic gas emission. They can use their normal manufacturing processes and resins. This opens the door to companies of all sizes to participate in the fire-protection field without further capital investment. In most cases, laminate cost is lower than for alternative ways of achieving the same degree of fire protection.
With increased emphasis on flame, smoke and toxicity performance of composite structural materials, particularly for mass transit and building applications, the market potential is seen to be substantial.

Other finalists in the Raw Materials category:
• A novel structural core composite materials for components of the auxetic type, presented by Chismatech (Italy) with its partner University of Catania (Italy).
• Reinforced composite rebar presented by EG Intellectural Asset Creative Development Co Ltd. (Taïwan) with its partner Rockey Ho (Taïwan).
• Lamilux’s heatable GRP presented by Lamilux Heinrich Strunz GmbH (Germany) with its partners Frenzelit (Germany) and Stadur (Germany).

Category: Process
Design and process development of non axi-symmetric four-axis integral filament winding of double-‘D’-shaped, all-composite road tankers

Winner: Modern Engineering Plastics Pvt, Ltd. MEPPL (India)
Partners: NGN Composites (India), CNC Technics Pvt. Ltd. (India), Crescent Consultants (United Kingdom) and TIFAC Govt. of India

Road tankers are used all over the world for transportation of water, edible oil, milk, chemicals and petroleum products. Traditionally, road tankers have a steel or aluminium body, with or without rubber lining inside. Metallic tankers are heavier with 12 to 15% of the liquid they carry and the rubber lining requires frequent repair and relining every four years. Unlike pressure vessels, road tankers for transportation of liquids under gravity are made of double-‘D’-shaped cross-sectional profiles in order to keep the overall centre of gravity low for better stability and vehicle road holding. No winding process for such non axi-symmetric profiles with integral-end dome winding has been developed so far. This innovation is intended for the filament winding of such tankers.
These composite tankers are more resistant to water and many chemicals. Their high strength-to-weight ratio and stiffness-to-weight ratio make them lighter and long lasting. They offer 45% weight saving over a steel tanker. The jointless winding of shell in an automated machine makes production
faster and the product stronger. Two tankers can be made in a day vs. several days for steel. A factor of safety of six or above is guaranteed without any resin leakage.

In September 2008, the AMC approved the launching of the tanker for field application. Negotiations are in process with a major truck manufacturer in India for marketing the product with annual initial sales of 500 tankers.

Other finalists in the Process category:
• A radius composite materials with innovative heat-directed properties presented by Hassan Associates Co., Ltd. (Japan) with its partners Japan Aerospace Exploration Agency (JAXA) (Japan) and Kyoto Institute of Technology (KIT) (Japan).
• A new kind of continuous-filament-winding machine for pipe production presented by Qingdao Longtech Machinery Co, Ltd. (China) with its partner Qingdao Deyili Pipe Co, Ltd. (China).
• Use of a new textile technology to produce fabrics with curved or annular structure in accordance with the shape requirements of composite products presented by Tianjin Polytechnical University Textile Institute (China).


Category: Automation
A laser-assisted thermoplastic tape placement process

Winner: Fraunhofer IPT (Germany)
Partners: Suprem SA (Switzerland) and Diehl Aircabin GmbH (Germany)

The new technique of laser-assisted thermoplastic tape placement which has been developed by the research consortium enables the fully automatic production of light-weight components from filament-reinforced plastics. Such components are required, for example, by the aerospace industry for horizontal stabilizers and fuselages and by other industries as well.
The newly designed process delivers substantially higher processing speeds (i.e. shorter production cycles) and requires a substantially smaller energy input during the manufacturing process than the conventional duroplastic tape placement technique which is currently used to produce these components. It allows the manufacturer, for example, to dispense with the hot-setting process, required to harden the currently used thermosets, which incurs high investment and process costs, because of its high energy consumption over several hours.

The breakthrough was made possible by some key contributions from the tape manufacturers Suprem SA who optimized their tape production processes to match the requirements posed by the laser-assisted tape placement technology, enabling the company to supply continuously improved tapes. The Fraunhofer IPT played the key role in the development project, having designed, developed and constructed the facility as well as the methods for the process analysis and process development and having assumed the responsibility of managing and coordinating the project. A vital contribution to the increases in component quality was provided by Diehl Aircabin who had provided real component specifications and verified these by subjecting component samples to technical inspections.

Other finalists in the Automation category:
• A precision injection pressure control for mould filling presented by Magnum Venus Plastech (USA).
• New Olmar generation autoclaves presented by Olmar (Spain) with its partner TC Industrial (Spain).

Category: Aerospace
Composite applications for radio telescopes (CART) project

Winner: National Research Council of Canada – Herzberg Institute of Astrophysics’ (HIA) Dominion Radio Astrophysical Observatory (DRAO) – (Canada)
Partner: Profile Composites Inc. (Canada)

The Composite Applications for Radio Telescopes (CART) project is an ongoing effort to investigate the application of composite materials to radio telescope structures to provide a cost-effective collecting area for the Square Kilometer Array (SKA). The result of this effort, the CART Mk 2 reflector, clearly demonstrates the potential of composite materials for the construction of radio antennas in the size range of 10 m to 15 m. The CART project research focuses very specifically on the technology development for the SKA, which will require several thousand 12-m class reflectors to be fabricated over a period of several years. Space communication ground arrays are another potential application where a number of reflector antennas are required.
The key benefit of CART technology reflectors is to make a high-performance yet cost-effective collecting area for the SKA possible, thanks to quantity production manufacturing techniques, high stiffness/lightweight structure, thermal stability, repeatable surface accuracy.
The Composite Applications to Radio Telescopes (CART) project was initiated in the spring of 2006. The first 10-m prototype reflector was completed in the summer of 2007. The result was a lightweight (~1000 kg), stiff reflector with a surface accuracy of 1.2 mm RMS. The Mk2 design consists of a one-piece surface and rim, eight radial beams and a central hub. The dish surface and rim was infused as one piece to reduce labour, elapsed hours, and time in mould. The hub and beams were fabricated in parallel and then bonded onto the surface/rim while it was still on the mould, capturing the surface shape. The separately moulded beams are made with a thin core in their webs and caps to stabilize their surfaces from local buckling, and are stronger, stiffer and lighter than the “moulded on foam”-cored Mk1 beams. In September 2008, the first prototype was removed from the test mount and after a preliminary surface measurement, the Mk2 was fitted in its place. The result is an improvement in surface accuracy from 1.2 to 0.5 mm rms and a significant reduction in production time. A costing analysis of this high-performance reflector indicates an in-production cost of ~$400/m². In 2008 the Composite Applications for Radio Telescopes (CART) project’s prime focus was on the production of the Mk2 prototype.

Other finalist in the Aerospace category:
• Local metal hybridization: the tendons of high-performance composite parts presented by German Aerospace Center, Institute of Composite Structures and Adaptive Systems (Germany) with its partners INEGI - Instituto de Engenharia Mecânica e Gestão Industrial (Spain) and EADS CASA Espacio (Spain).


Category: Building & Construction

FRPM Pipes for sewage system

Winner: Kurimoto Plastics Co., Ltd. (Japan)
Partner: National Institute for Rural Engineering (Japan)


The FRP layer consists of high-strength glass fibres wound in the circumferential and axial directions by the filament winding process and hardened by thermosetting unsaturated polyester resin. The included resin mortar is a polyester concrete made from selected fine sand hardened by unsaturated polyester resin, having a compressive strength several times as high as an ordinary cement concrete. The interior and exterior FRP layers bear the bending stress of pipes, while the middle resin mortar layer keeps each FRP layer at a certain interval and transmits shearing force. Dynamically, this structure is ideal, in particular excelling in strength against external pressures such as soil and truck load, and against as various internal pressures as well.
FRPM pipes have such excellent corrosion resistance properties that they can serve as sewage pipes for a long time, whereas concrete sewage pipes are corroded by the highly acid environment in sewage systems. FRPM pipes have such excellent earthquake-proof properties that they do not crack even in case of strong earthquake. These flexible pipes can adjust to ground displacement, due to the flexibility and elasticity of joints. The strength of FRPM pipes is great enough to protect them from internal and external pressure. As they are flexible, the stress occurring in the ground is lower than those of non-flexible pipes. Therefore, they don’t require any special foundation, regardless of ground depth, deep or shallow. Superior dimensional precision at joints and an original rubber ring design guarantee outstanding water-tightness, with no risk of leakage or external injuries.

FRPM pipes are substituted for steel pipes and concrete pipes to reduce costs and to prolong the system’s service life. The applications of FRPM pipes are the following: sewage, jacking pipes, water for irrigation, tube well casing & screen, protection for power & communication cables.
Kurimoto Plastics CO., Ltd. has developed rehabilitation methods for overage pipelines or tunnels through a joint research project with the National Institute for Rural Engineering. One is the SIL method using thin-walled FRPM pipes to rehabilitate over-aged pipelines. Another is the horseshoe-type pipe-in-tunnel construction method to rehabilitate over-aged tunnels. These methods allow fast rehabilitation while reducing costs.

Other finalist in the Building & Construction category:
• Bamboo composite pole presented by Mahindra Composites (India) with internal teams to develop the winding machine, end castings, connectors and applications.

Category: Sports and Leisure
One-piece “jointless” composite ice hockey

Winner: Composites Busch SA (Switzerland)
Partners: Huntsman (China) and EPFL (Switzerland)

Ice-hockey players are always looking for the right combination of opposing features – flex, band, stiffness and whip. The challenge is designing an ice-hockey stick that has good stick and blade slashing properties, as well as bending and torsion features. The player is not only hitting the puck directly, he is sometimes hitting the ice. The energy stored during this shock needs to be released efficiently onto the puck, and this is where the one-piece “jointless” design brings full benefits. The energy is smoothly and accurately transferred through the stick to the blade and then to the puck with total control from the player, who always keeps close and direct contact with the puck. Huntsman Advanced Materials provided the easy-to-process Araldite® NanoTech composite RTM system, blended with organic nano-particles that exhibit outstanding toughening effects. EPFL independently quantified and validated the properties (toughness and resistance to impact and vibration).

This only one-piece “jointless” composite ice hockey combines good stick and blade slashing properties, as well as bending and torsion features. The one-piece design allows the energy stored during the shock on the ice to be released efficiently onto the puck. It has better solidity and durability, and a longer lifetime. Fewer vibrations are transmitted to the body and therefore reduced associated injuries.

Today, Busch is producing 5,500 hockey sticks a year (mainly custom sticks). The goal is to increase production by 25% to reach 7,000 sticks.

Other finalists in the Sports and Leisure category:
• Alpico ice-axe in three foldaway sections presented by Polynt SpA (Italy) with its partners Soluzioninventive Srl (Italy) and Aludesign SpA (Italy).
• CFS CarbonFibre stone to replace wood, aluminium, steel and concrete for almost any kind of application in mechanical engineering and the building sector with superior properties presented by TechnocarbonTechnologies (Germany) with its partner GCERM Foundation.


Category: Transportation/ Marine
Development of an all carbon hull for Damen Shipyards DI 1102 Interceptor boats.

Winner: DK Composites (Malaysia)
Partner: Damen Shipyards Gorinchem (Damen)

The Damen Interceptors 1102 are a new generation of ultra-fast boats featuring special hulls made entirely out of carbon and glass fibre composites. These boats can reach operating speeds of 60 knots, are highly manoeuvrable, and best suited for maritime law enforcement operations.
The need to protect the world against smugglers and other undesirable elements at sea has generated a growing demand for interception boats. The fast-moving Damen Interceptor 1102 is Damen’s response to this demand.

The structural design uses advanced carbon and glass composites. The Interceptor has passed a stringent set of tests with flying colours. The results were excellent and show just how solid the Damen Interceptor 1102 is. The Damen Interceptor 1102 is a small, lightweight craft, which makes it inexpensive not only in terms of the purchase price, but also in terms of fuel consumption. It combines reliable technology with good seagoing behaviour and high speeds. It’s ideal for intercepting fast-moving targets.

Having heard of the company’s reputation for fabricating high-quality composites hulls, Damen commissioned DK to build the first Damen Interceptor 1102 in 2007. The job was completed in the specified time and passed all sea tests conducted in Port Dickson, as well as harsh testing in the rough North Sea in Europe. In 2008, Damen awarded a contract to DK Composites Sdn Bhd for the building of four Damen Interceptors 1102 boats. This order concerns the first “production series”. One of these can be used as demonstrator for other potential customers in other parts of the world. It is also hoped that the Malaysian Maritime Enforcement Agency will also test this boat for their interceptor operations in Malaysia.

In the near future, Damen intends to be able to deliver one DI 1102 unit every two weeks. At the moment, Damen and DK Composites are discussing the series production of a 15m fully-composite pilot boat. They plan to extend their co-operation even further with the production of larger interceptor craft and various other Damen vessels between 15 and 20 m.


Category: Transportation/ Railways
A railway composite insulator

Winner: En Liang (Taiwan)
Partner: Brecknell Willis & Co. Ltd. (Taiwan)

En-Liang has been working on railway insulators with Brecknell Willis & Co. Ltd. Taiwan (short name BW Taiwan) since 2000. The insulator material (BMC/SMC) developed by En-Liang is perfect for outdoor insulation applications. In 2008, En-Liang worked with BW Taiwan to develop a new insulator for Taiwan’s Tao-Yuen Airport metro line which connects the airport to the Taipei area. This time, En-Liang designed the insulator shape directly and developed a suitable material according to the customer's requirements.

Metro systems will be more and more popular in the future. This special material and design process are perfect for meeting different environmental conditions and different transportation systems.
The advantages of this insulator material are high insulation strength and a substitute for ceramic insulators as well as high strength and a partial substitute for the metal support used for supporting the insulator. It also offers excellent outdoor application.

Ansys software was used to analyse whether the shape would be capable of withstanding these forces in order to prevent future failures when the mould is completed. The designed shape not only met the customer's requirements but also was compatible with the moulding conditions used. As a
professional moulder, En-Liang knew how to mould a strong insulator when changing the design. As a result, the actual insulator mould and the moulding stage were a great success. The BMC/SMC material was created specially for the railway insulator application. It is UL-V0 approved and qualified by the customer for outdoor applications.

Other finalists in the Transportation category:
• “BUCCHUS” brand G-FRP/C-FRP car aero parts hand lay-up and/or L-RTM processed presented by FRP Services & Company (Japan) with its partner Fusso Trading Co.,Ltd. (Japan).
• Composite recreational mobile home and shelter systems presented by Penguin Composites Pty Ltd (Australia) with its partners Innovan Campers and Caravans (Austalia) and Attard Agency Pty Ltd (Australia).

Pictures of the winners available on request to Apocope

JEC Composites, which promotes the use of composite materials worldwide, informs and connects 250,000 composite professionals, offering them a comprehensive service package: the JEC publications – including strategic studies, technical books and the JEC Composites Magazine – the JEC Composites weekly international e-letter and the French e-letter JEC Info Composites, the JEC Composites Show in Paris (world and European leader), the JEC Composites Asia Event, the www.jeccomposites.com website, the JEC Composites Forums and Workshops, and the JEC Innovation Awards Programme.

Source : JEC