JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 21

even entire wheels. Only the drivetrain elements – chain, sprockets, chainrings – seem to be exempt from this development on account of the specific constraints involved (high pressure, abrasion, small dimensions, etc.). By way of example, a carbon frame of the 1990s weighed 1500 g with tube walls 2.5 mm in thickness, whereas its modern equivalent weighs 1000 g for wall thicknesses close to 1 millimetre. JCM: The trend for the "one-piece" offers many advantages both with respect to the product itself and in terms of production. J.M.G.: Logically, the first "carbon" frames were produced on the basis of tubular elements assembled by means of bonding to light alloy couplings, offering performance enhancements that were already significant when compared to metal frames. The first frames with carbon couplings appeared several years later, alongside the first so-called "monocoque" frames. At that time, the advantage was with bonded assemblies which, thanks to greater mastery of the subassembly manufacturing process, offered lighter, better performing products, particularly inasmuch as bonded assemblies – the Achilles heel of the first carbon frames – had been perfectly mastered. Today the situation is somewhat different. Improved manufacturing of complex structures now makes it possible to benefit from all the

advantages of a "monocoque" construction, so dispensing with the bonding assembly times, certain reworking operations and complex component management. Monocoque construction also makes it possible to "free up" the bonding zones, subject to extreme technical constraints, for improved design and optimization of each frame size. This is therefore of dual interest: both industrial, through simplification of the industrial process, and technical, through improved quality of design and optimization. JCM: TIME has chosen the braid + RTM technique rather than the prepreg technique (fabric + UD). Why this choice? J.M.G.: TIME chose to use braid + RTM technology because it is perfectly suited to the manufacturing of small diameter tubular structures, which applies perfectly to the bicycle frame. In making our choice we also took into account the notions of safety, important in the case of the competition bike subject to the risk of falls in the group of riders, but also in relation to road traffic risks, particularly during training, or stresses linked to bicycle transportation (in car boots, by air, etc.). Braided structures offer the guarantee of fibre continuity right to the outer surface of the part, while the mechanical interlinking of the fibres ensures good resistance to impact and cracking, particularly in the vicinity of drill holes required for attaching accessories (bottle holder, cable stops, etc.). They also offer perfect control over the mechanical characteristics thanks to optimized fibre orientations (from 15° to 65°), with the directional laying of exotic fibres making it possible to generate nuanced behaviour that is hard to equal with other technologies. TIME also chose to mould its composite parts by RTM using fusible cores. This technology guarantees

Hybrid braid(carbon/vectran)

excellent thickness control, along with the perfect cohesion of the different layers. (image de préforme) This also makes it possible to generate complex internal forms such as the Stiff reinforcement (image) found in the steerer tubes, or to position reinforcement zones with ease. The matrix is a high-performance epoxy resin with a Tg of 125°C. The combination of a braided structure and RTM moulding also ensures excellent manufacturing reproducibility by simplifying the layup process (dry fabric that is easy to handle and non-irritant for operators). JCM: Is it possible to quantify the amount of carbon used worldwide in bicycle production, based on an average weight per bike and the number of bikes manufactured today? J.M.G.: Worldwide production accounts for around 100 million bikes, all types included. If you consider that sports bikes represent around ± 5% of the total volume, i.e. 5 million bikes, the population of carbon bikes should represent 30% of this total, in other words approximately 1.5 million units. With the average weight of a racing bike at approximately 7.5 kg, and the carbon content representing an average of 2 kg, the "bike" business taken as a whole represents an annual consumption of 3,000 metric tons of carbon fibre.

Carbon frame preform

No60 October 2010 / jec composites magazine

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JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010

Cover
Contents
Gurit inaugurates new Red Maple tooling production site
Toho Tenax steps up its carbon fibre business in Asia
IDI Composites International announces installation of automated BMC production line
NEWS WORLDWIDE
Boeing to increase its composite production in Tianjin
Airborne attracts growth capital
Celanese increases PPS production
Umeco extends commercial relationship with Rolls-Royce
Agenda of events
Raw materials: Matrix resin - Improving the compression strength of composites
Market survey - Para-aramid fibres for composite applications: niche market
BUSINESS
Trend - TIME : innovation in bicycle products
Niche market - An effective way to store energy
Conferences and Forums - Composites for a sustainable growth in Asia
Participating companies
FEATURE
JEC Asia Innovation AwardsProgramme 2010
BUYER'S GUIDE
Innovations - JEC Innovations report 2010
Singapore - Goodrich celebrates 15 years of successful operation in Singapore
Tempco Manufacturing Singapore: an appetite for innovation
Country of Honnor : India - Balaji Fiber Reinforce: more than just a pipe specialist!
CPE, well beyond the Indian subcontinent!
ICP India, a processor brimming with projects
USER'S PLATFORM
Successful partners - Low-cost structural thermoplastic composites for transport
First night flight ever by a solar plane ever made
Composites in the world - The Mamba Helmet
Composites take inkjet systems to new levels of performance
Marine - Flexible core for 2012 Olympic match racing boat
KNOW-HOW
Raw Material - Vinyl acetate-based alkaline-resistant scrim binder
Reinforcement - The first long-glass-fibre PVC composite
Design tool - Modelling of textile composites
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 3
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 4
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 5
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Umeco extends commercial relationship with Rolls-Royce
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 9
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 10
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 11
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Raw materials: Matrix resin - Improving the compression strength of composites
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 15
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 18
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Trend - TIME : innovation in bicycle products
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Niche market - An effective way to store energy
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 23
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 24
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JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 25
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Conferences and Forums - Composites for a sustainable growth in Asia
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - FEATURE
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - JEC Asia Innovation AwardsProgramme 2010
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 31
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 32
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 34
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - BUYER'S GUIDE
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - BG-Ad
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JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Innovations - JEC Innovations report 2010
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 38
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 39
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 40
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Singapore - Goodrich celebrates 15 years of successful operation in Singapore
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 43
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Tempco Manufacturing Singapore: an appetite for innovation
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 45
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Country of Honnor : India - Balaji Fiber Reinforce: more than just a pipe specialist!
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 47
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - CPE, well beyond the Indian subcontinent!
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 49
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - ICP India, a processor brimming with projects
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Successful partners - Low-cost structural thermoplastic composites for transport
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 53
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Composites take inkjet systems to new levels of performance
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Marine - Flexible core for 2012 Olympic match racing boat
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 56
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 57
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Raw Material - Vinyl acetate-based alkaline-resistant scrim binder
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 60
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Reinforcement - The first long-glass-fibre PVC composite
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 62
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - Design tool - Modelling of textile composites
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 64
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 65
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 66
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 67
JEC COMPOSITES MAGAZINE - Issue #60 - Special JEC Asia - October 2010 - 68
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