JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 21

Snap-cure material toolbox
for high-volume applications
Design-to-cost

lntegrating design and costing

MANUFACTURING

Mass production

21
24

mass production MANUFACTURING

Snap-cure material toolbox
for high-volume applications
SGL has developed a new resin system with a few minutes' cycle
time and a high glass transition temperature. This new system is the
essence of the company's new toolbox for high-volume high-performance solutions.
Dr. Max von BistraM,
Head of Composite Material
Development,
Dr. thoMas MeinharDt
Senior Project Manager -
Material Development
SGL

O

ver recent decades, there have been
some changes in production processes for fibre-reinforced polymer
(FRP) components. But the most obvious change that still needs to be made is
to speed up the production of FRP parts.
We are talking here about several hundred thousand composite parts per year
for serial automotive production. To fulfil
this task cost-efficiently, cycle times need
to be much faster than the known curing
times for traditional epoxy resins of 10-20
minutes in compression moulding processes.
A few minutes' cycle time! This requires
radical changes in production processes
and new concepts for the materials used.
It means that for a suitable matrix system,
the choice is either to go for thermoplastic
materials or use highly reactive thermoset
systems, so-called "snap-cure" resins.

Cycle time
Epoxy-based prepregs with several
minutes' curing times are already available
but unfortunately, such systems are not
ideal for adequately solving the issue.
To achieve the very short cycle times required, variothermal curing cycles cannot
be the solution anymore. It will take longer
to heat and cool the moulding setup than
to cure the part. Even replacing autoclaves
by less sluggish hot presses and using very
intelligent tooling concepts cannot change
this picture completely. Isothermal curing
will obviously be the most efficient, as it
consumes the least amount of energy and
time.
But with epoxy-based prepregs, that have
already been commercialised, the maximum glass transition temperature of the
resin systems is often not reached; it does
not even come close to the level of the curing temperature. This means the matrix is
still in its rubbery state, and so the dimensional stability of the material is usually
not sufficient for hot demoulding.
A real "snap-cure" prepreg system has to
provide two things: fast reaction (e.g. 2-3
minutes at 150°C) and rapid build-up of
the crosslink density.

Shelf life
Another requirement often called for is
the right balance between reactivity and
storage life, especially in the case of highly
reactive resin systems. High reactivity in
general reduces the shelf life of a prepreg.
However, it must be possible to store the
prepreg for some time at room temperature to avoid the high cost of cold chain
logistics.
In our experience, the target must be at
least one month's storage life under ambient conditions without changing the
properties of the prepreg significantly.
Tack & automation
Automation is the next relevant change
to consider in the production of FRP
parts. The level of automation has already
increased a lot and continues to grow.
Unfortunately, automated processes require a rather paradoxical set of characteristics. For example, for "pick-and-place"
systems, some stickiness is needed to
place the material securely in the mould
and onto previously inserted layers but
at the same time, it is important to ensure
that the grippers can easily release the prepreg. Similar requirements are necessary

No113 June 2017

/ jec composites magazine

21



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #113 - June 2017

Cover
Edito
Opinion: High temperature composites
Contents
NEWS
In brief
Strategy
Agenda
BUSINESS
Recycling
Second life
Thermoset resin - Part A
MANUFACTURING
Mass production
Design-to-cost
Feature Construction - The future of building
Editorial
JEC Innovation Awards Programme
International JEC Conferences: knowledge and networking
Education
Education
Domes
Sustainable development
Facade
Interior
Safety
Biocomposites
SOLUTIONS
Marine
Automotive
Aircraft
In the world
TECHNOLOGY
Mecanics
Simulation
Technical textile
Repair
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 76
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Opinion: High temperature composites
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 10
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Strategy
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 12
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Recycling
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Second life
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 18
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Thermoset resin - Part A
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 20
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Mass production
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 22
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 23
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Design-to-cost
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 25
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 26
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Editorial
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - JEC Innovation Awards Programme
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 30
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 31
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - International JEC Conferences: knowledge and networking
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 35
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Education
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 37
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Education
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Domes
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 40
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 41
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Sustainable development
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 43
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Facade
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 45
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Interior
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 47
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 48
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Safety
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 50
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Biocomposites
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 52
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Marine
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 54
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Automotive
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Aircraft
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 57
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - In the world
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 59
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Mecanics
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 61
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 62
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Simulation
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 64
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 65
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 66
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Technical textile
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 68
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 69
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Repair
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 71
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 72
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 73
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #113 - June 2017 - 75
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