JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 68

KNOW-HOW Process Rapid processing of tubular parts made of thermoplastic composites RocTool has developed Fast Tube®[1] to adapt its Cage System® process[2] to a range of different plastic/composite applications. This new inductive heating system will help the company establish a position in the market for tubular parts with high mechanical properties. This process is fairly long and energy consuming, so it is not very compatible with the high throughput demanded in thermoplastic applications. For this reason, tubular parts are usually made of thermoset resin, which lend themselves well to the long cycles essential to thermo-regulated processes. Processes like pultrusion or filament winding are used for more specific applications, of course, but they are not suitable for all types of materials and are often reserved for applications that involve very specific mechanical stresses. JOSÉ FEIGENBLUM, R&D MANAGER, DAMIEN PERRIER, R&D ENGINEER ROCTOOL T o reduce weight and costs in the plastic industry, there is a strong need for a technology capable of producing hollow parts with a short cycle time. RocTool has now adapted its tool-surface heating technology to the tube market for that very purpose. RocTool technology uses induction to heat up tool surfaces rapidly and allow cool down fast too, a method that provides advantages such as reduced overall cycle time, improved surface quality, the possibility to use engineering materials, and more. Cage System® overview RocTool’s core technology comes in several different versions for rapid processing of plastics and composites. It uses induction to instantly heat the moulding surface only. This considerably reduces the energy consumption compared to a standard process where the entire mould must be heated, so that it is impossible to cycle the heating and cooling steps in an industrial configuration [3]. As shown in figure 1, an electrical current I is sent through the inductor surrounding the mould halves, creating an electromagnetic field. This generates induced currents I' (governed by Lenz's law) that are located in the electromagnetic (EM) skin depth δ. Each “eddy” current loops around one of the mould halves in opposite directions one from another, alternately encountering a nonmagnetic material and a magnetic material. State of the art in thermoplastic processing There are four main stages in a standard thermoplastic composite process: - the material is preheated using external means such as an infrared oven or a convection oven; - the preheated material is transferred to a forming mould regulated at the part release temperature; - the tool is closed and the material moulded into shape; - the shaped part is cooled and released from the mould. This standard operating procedure is not possible for tubular parts, due to difficulties placing the material. Both power and moulding pressure must be applied at the same time, with the material already in the mould. There is another process for making thermoplastic tubes, however, consisting in the following stages: - the material is placed in a cold mould and pressure is applied using a flexible means of compaction; - the mould is transferred to a heating plate and heated for about 15 minutes at high power; - the mould is transferred to a cold plate and cooled for about 15 minutes. Fig.1: Cage System® principle Differential surface heating is created between the two materials, by injecting a high quantity of energy (high magnetic output) into a small volume for the magnetic material (δ<<mm) compared with injecting a medium quantity of energy into a bigger volume JEC Composites Magazine / No42 July-August 2008

JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008

Cover
- Applications Composite aerodynamic front-end cabs for passenger trains
- Citadel Plastics acquires BMC Inc.
- Niche market Durable concrete formwork system
- Cool radiators for hot trucks
BUSINESS - Market survey Hexcel anniversary in 2008 marked by investment
- Raw material Corrosion resistance of High-Performance Glass fibres
USERS’ PLATFORM KNOW-HOW Composites in the world Carbon fibre iPhone case
- New generation of hydrogen cars
- Architecture Composites and architecture: the perfect couple
- EEE enclosures
- Thermoplastics Reinforced thermoplastics enable affordable storm-resistant structures
- Gurit signs 4-year supply agreement with EADS
Innovations
- TechnoCompound expands its production
- SGL Group opens central technology and innovation centre
Agenda of events
FEATURE - Partnership Smart composite materials project DECID2 for structural applications
- Hankuk Fiber Group, one man’s determination
- Process Rapid processing of tubular parts made of thermoplastic composites ......................................
- Process Polydicyclopentadiene winning over construction professionals
- Trenchless pipes’ installation
- Corrosion Composite linings for corrosion protection
- Unmanned aircraft made of high-temperature prepreg
- High impact-strength spokes
NEWS WORLDWIDE - Companies GKN Aerospace creates repair facility for metallic and composite structures
- Raw material SMC/BMC compounds for building and construction
- Trends Coatema expertise: coating and materials handling technologies for prepregs
- The world’s largest offshore wind farm project
- Subsea structures
- Design “Eco-characterisation” of composite materials
- Special JEC Composite Asia
- Hitco to supply components for the B787
- Sandwich structure Polypropylene honeycombs for a variety of uses
- Head restraint system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Cover
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - NEWS WORLDWIDE - Companies GKN Aerospace creates repair facility for metallic and composite structures
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Hitco to supply components for the B787
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Hankuk Fiber Group, one man’s determination
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Agenda of events
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - Innovations
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - BUSINESS - Market survey Hexcel anniversary in 2008 marked by investment
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Niche market Durable concrete formwork system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Trends Coatema expertise: coating and materials handling technologies for prepregs
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - FEATURE - Partnership Smart composite materials project DECID2 for structural applications
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Architecture Composites and architecture: the perfect couple
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Raw material SMC/BMC compounds for building and construction
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 34
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Process Polydicyclopentadiene winning over construction professionals
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Thermoplastics Reinforced thermoplastics enable affordable storm-resistant structures
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 42
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Sandwich structure Polypropylene honeycombs for a variety of uses
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 44
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Corrosion Composite linings for corrosion protection
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 47
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - High impact-strength spokes
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Head restraint system
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Applications Composite aerodynamic front-end cabs for passenger trains
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Trenchless pipes’ installation
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Unmanned aircraft made of high-temperature prepreg
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Subsea structures
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - 57
JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Design “Eco-characterisation” of composite materials
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Raw material Corrosion resistance of High-Performance Glass fibres
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Process Rapid processing of tubular parts made of thermoplastic composites ......................................
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JEC COMPOSITES MAGAZINE - Issue #42 - July/August 2008 - - Special JEC Composite Asia
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