JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 58

KNOW-HOW
Raw material

g…/… Latent acid catalysts for process control of phenolics

The decomposition of hydroxylamine itself rather than the salt, an action that completely releases the acid to begin the polymerisation, gives the hydroxylamine based latent acid longer-term stability and lower activation temperature than other latent acids.

58

Fuel cell description
Mix life before pressing (Minutes)
7 11 9.73 9.76 16 20 25 30 34 39 44 49 9.84 9.83 9.96 9.99 10.00 10.08 10.14 10.33

For compression moulding of Bac2’s composite bipolar plates, mix life issues were prevalent. A graphite composite pre-mix of phenolic resin and a strong acid began reacting immediately when mixed together. Moulding properties were affected within minutes. Typically, a reactive pre-mix will produce mouldings which are increasingly heavier and thicker over the duration of the mix life as flow properties of the mix reduce. Table 1 shows where a graphite composite pre-mix has been compression moulded. The mouldings produced after 7 minutes of mix life are significantly different to the moulding produced after 49 minutes. The thickness of the moulded part has increased from 3.129 to 3.442mm with a corresponding weight gain from 9.73 to 10.33g. The conductivity of the moulded plate at the same time is reduced.

Table 1: The effect of mix life on the flow propeeties of an uninhibited acidified resole composite mix

and end plates for a mass market will be vital to the commercialisation of fuel cells. Bipolar plates and end plates are key components in a fuel cell stack, making up about 80% of the weight. They need to be mechanically strong, electrically conductive, chemically stable and low cost. For mass production of fuel cells, moulded plates will likely be produced from polymer composites. The development of CSR Fig. 4: A composite bipolar plate hydroxylamine-based latent acid catalysts enabled Bac2 to produce a stable pre-mix formulation that can be compression moulded after six months storage at room temperature to produce a plate of the same dimensions and properties of a moulding produced after 24 hours (Table 2).
Table 2: The consistent moulding properties of a storage stable acidified resole composite mix

Plate weight (g)

Plate thickness (mm)
3.129 3.137 3.156 3.164 3.193 3.202 3.212 3.224 3.318 3.442

Through plane conductivity (Scm-1)
38.35 33.06 38.68 31.59 27.79 29.56 25.84 26.52 18.62 19.35

Stable latent catalyst pre-mix Days storage
1 30 60 180

Plate weight (g)
9.86 9.87 9.85 9.89

Plate thickness (mm)
3.01 3.03 2.99 3.02

Through plane conductivity (Scm)
34.2 35.1 34.8 35.0

Fuel cells produce electrical power for both stationary and portable applications. To produce useful currents and voltages, individual cells are connected in series to form a stack, as in Figure 3. Adjacent cells are typically separated by bipolar plates, which perform several functions including that of an electrically conductive current collector. Other functions of the bipolar plates include transportation of fuel (usually gaseous) along the flow channels on the sides of each plate to enable its distribution to the active surface layers on the fuel cell membrane assembly. The ability to economically produce bipolar plates

jec composites magazine / No61 November - December 2010
Fig. 3: A fuel cell stack

Bac2 is now broadening the uses of the CSR catalysts to phenolic composites and other acid catalysed thermosetting polymers including furan and aminoplasts. In-house phenolic BMC mixes have been formulated and compression moulded after 2 months. Phenolic and furan pre-preg, sheet moulding compound, pultrusion, RTM and adhesives are also in development.

As resin systems vary widely in terms of pH sensitivity, Bac2 offers a twin catalyst option, allowing blending of the catalysts to suit the reactivity of the resin system. Customised formulations, which are added to pre-polymeric mixes, are created from a tailored combination of CSR20 and CSR100 catalysts. CSR20 facilitates lower catalyst levels and fast curing. CSR100 produces long pot life o with rapid curing above 120 C. With an appropriate mixture of the two, the pot life and cure rate of pre-polymeric mixes is precisely controlled. n
More information: graham.murray@bac2.co.uk www.bac2.co.uk Referrence [1] Louis Pilato’s latest book, Phenolic Resins: A Century of Progress, references the action of CSR catalysts here: http://tinyurl.com/acidcatalyst


http://www.bac2.co.uk http://www.tinyurl.com/acidcatalyst

JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010

Cover
Contents
NEWS WORLDWIDE
Companies
Spirit AeroSystems and GOL Linhas Aereas Inteligentes enter into agreements
CTRM and CTL to commercialize composites testing in Asia
IDI Composites International announces installation of automated BMC production line
Umeco and Shanghai Leadgo Technology form a joint venture in China
SAIC awarded USD 11 million contract to deliver manufacturing facility for composite building materials
Airbus completes allocation of A350 XWB airframe work packages to China
Hexagon Composites signs new major contract with Daimler AG
National Aerospace Laboratories: incisive know-how
Innovations - Twelve companies rewarded by JEC and CCE for their composites innovations
Agenda of events
Equipment: Welding - Increasing bond strength and reducing defects in ultrasonic welding
BUSINESS
Market survey - Aerospace composites in Quebec: a wealth of players and R&D
AN INTERVIEW WITH JACQUES CABANA PRESIDENT & GENERAL MANAGER FDC COMPOSITES Inc.
Niche Market - Tool-side breathing allows BAE Systems to manufacture its new UAV
Trend - Composites and the carbon label
FEATURE - AUTOMOTIVE
Data - World ranking of manufacturers years 2009
Trend -Formula One experience to drive forward other industries
Application - BMW's MCV, the first mass produced car with a carbon passenger cell
An interesting solution for NASCAR race engine alternators
Prepreg materials investigated as a storage battery for future cars
Research & Development - Lamborghini prepares for the future with a new carbon-fibre research development
Environment - How adhesives reduce emissions, minimize waste and improve recycling
FRP recycling in Europe, North America and the Pacific Rim area
USER'S PLATFORM
Composites in the world - Agile as a snake for ice climbing
Recyclable emergency snow shovel
Superbus: an innovative public transport concept
Successful partners - Conseil & Technique, an SME dedicated to the development of new products
Application - Advanced graphite composite bipolar plate for fuel cells
KNOW-HOW
Software - four factors drive the development of superior wind blades
Simulation - Bespoke simulation for thermoplastic composite
Raw material - Latent acid catalysts for process control phenolics
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 3
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 4
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 5
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Hexagon Composites signs new major contract with Daimler AG
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - National Aerospace Laboratories: incisive know-how
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Innovations - Twelve companies rewarded by JEC and CCE for their composites innovations
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Equipment: Welding - Increasing bond strength and reducing defects in ultrasonic welding
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Market survey - Aerospace composites in Quebec: a wealth of players and R&D
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 15
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - AN INTERVIEW WITH JACQUES CABANA PRESIDENT & GENERAL MANAGER FDC COMPOSITES Inc.
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Niche Market - Tool-side breathing allows BAE Systems to manufacture its new UAV
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Trend - Composites and the carbon label
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 22
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 23
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Data - World ranking of manufacturers years 2009
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 25
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Trend -Formula One experience to drive forward other industries
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Application - BMW's MCV, the first mass produced car with a carbon passenger cell
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - An interesting solution for NASCAR race engine alternators
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Prepreg materials investigated as a storage battery for future cars
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Research & Development - Lamborghini prepares for the future with a new carbon-fibre research development
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Environment - How adhesives reduce emissions, minimize waste and improve recycling
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 35
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - FRP recycling in Europe, North America and the Pacific Rim area
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 38
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 39
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 40
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 42
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 43
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Superbus: an innovative public transport concept
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Successful partners - Conseil & Technique, an SME dedicated to the development of new products
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 46
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Application - Advanced graphite composite bipolar plate for fuel cells
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 48
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 49
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Software - four factors drive the development of superior wind blades
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Simulation - Bespoke simulation for thermoplastic composite
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 55
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 56
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - Raw material - Latent acid catalysts for process control phenolics
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 58
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #61 - November/December 2010 - 60
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