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tesDr. Kay
ROHACELL® Triple F
- A Novel Particle Foam
Complex shaped PMI Foam Cores for highly efficient FRP Composite Sandwich Fabrication for low to high volume applications
SAMPE Brazil Conference 2015 22nd
October 2015, Sao Jose dos Campos, Brazil
Fabio Tufano M. Alexander Roth, Dr.-Ing. Technical Sales & New Business Director ROHACELL® Americas &
Development South America Vice President
Evonik Degussa Brasil Ltda. Evonik Foams Inc.
1. Sandwich Cores Requirements and Overview
2. Manufacturing Process of PMI Rigid Foams
3. Advantages of PMI In-Mold Foaming (IMF)
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 2
Slide 3
Definition and Layup
of Sandwich Structure
A structural SANDWICH is a special form of a composite that combines at least two different materials by bonding them to each other so as to utilize the properties of each separate component to the structural advantage of the entire assembly.
Resin, e. g. EP
Resin, e. g. EP
Core, e. g. PMI-Foam
Fibers, e. g. CF, GF
Fibers, e. g. CF, GF
FRP Face Sheet
FRP Face Sheet
Source of image: http://www.bluewatersupply.com/marine_composites_DIAB_Divinycell.aspx, 08/31/2015
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Slide 4
The Sandwich Effect
Source of image: http://www.neo.co.th/product_c013%20en1.php, 08/31/2015
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Sandwich Structures are very suitable for bending & axial compressive loaded parts to increase: Bending stiffness and strength Buckling and crash performance
Lightest Solution!
Slide 5
Function of Core Material
Mainly:
• Keep Skins at Distance
• Stabilization of Skins (FRP Layers)
• Transferring Shear Forces
from one Skin to the other Skin
But also:
• Absorption of Impact Loads
• Thermal Insulation
• Acoustic Insulation
• Vibration Dampening
• …
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Requirements for Sandwich Cores
Requirement Core properties
Lightweight design High mechanical strength at low density
High surface quality Fine and closed cell foam
Fast cycle times High temperature & high compression resistance
Processability Easy to shape
ROHACELL® is a PMI-based structural foam core that
meets all requirements for fast curing processes.
Composite sandwich construction is an emerging option to
meet innovation demands coming from many industries, from
automotive up to sport industry.
It leads to the lightest available final parts and can also offer
significant cost reduction in mass production.
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 6
Biggest Hurdle for more Composites:
Manufacturing Costs
Overall cost
current
composite costs requested
costs
100 %
0 %
Source of image: http://ecomento.com/2013/12/12/carbon-fiber-wont-make-bmw-i3-insurance-repair-expensive/, 08/31/2015
Requirements from OEMs: “Competitive costs for composites”
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 7
Overall cost
current
composite costs requested
costs
100 %
Production process has the biggest potential to
decrease costs! 0 %
Requirements from OEMs: “Competitive costs for composites”
Source of image: http://ecomento.com/2013/12/12/carbon-fiber-wont-make-bmw-i3-insurance-repair-expensive/, 08/31/2015
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 8
Biggest Hurdle for more Composites:
Manufacturing Costs
Production Processes
Trend toward mass production
Hand Lamination, Autoclave-Technology
(Prepreg, Honeycomb)
HP-RTM, Press Moulding
(Prepregs, Organosheets, Dry Fabrics/Liquid Resins,
Foam Cores)
Number of Parts
Slow
Fast
Production
process
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 9
Production Processes
Core IR Press
Press IR
Prepreg 180 °C
Dry-Compression
Press
Press
Epoxy
140 °C
Core IR
IR
Wet-Compression
shorter production cycle time of composite parts
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 10
Finished part Textiles
Core
Pre-formed
Sandwich Positioning
in mold Injection
Vacuum
(optional)
Pressure
Epoxy
• temperatures of 80-140°C
• pressures of 20-80 bars
A fast curing process requires a core to withstand:
Production Processes
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 11
Production Processes
Requirements of the Core Materials:
• Resistance to Process Pressure
• Resistance to Process Temperature
• Creep Resistance
• Compatibility with any Matrix System
• Closed Cells
Source of image: http://www.evcarlife.com/bmw-i3-lifedrive-architecture/, 08/31/2015
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 12
Applications
Requirements of the Core Materials:
• High Strength
• High Stiffness
• Fatigue Behavior
• Buckling Behavior
• Crash Performance
Source of upper image: http://www.cbc.ca/news/business/bmw-canada-electric-car-comes-with-solar-panel-discount-1.2700033, 08/31/2015
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 13
• Low Weight = Low Density
• Low Uptake of Resin
• Adhesion to Cover Layers
Medley of a few Applications with
ROHACELL® inside
Medical Sports
Wind Energy
Consumer Electronics
Aerospace
Automotive Ship Building
Radome & Antennas
Source of images: The Use of PMI Foams for Sandwich Applications in the Aerospace Industry, 2nd BCCM, Sao Jose dos Campos, Brazil, 17th of September 2014
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 14
1. Sandwich Cores Requirements and Overview
2. Manufacturing Process of PMI Rigid Foams
3. Advantages of PMI In-Mold Foaming (IMF)
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 15
Conventional Production of ROHACELL®
1. Liquid Monomer Solution
2. Co-Polymer Sheet
Page | 16 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
3. Raw Foam Block
4. Cut-to-Size Foam Sheets
1. Liquid Monomer Solution
2. Co-Polymer Sheet
Conventional Production of ROHACELL®
Page | 17 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
5. Net-Shaped cores
3. Raw Foam Block
1. Liquid Monomer Solution
2. Co-Polymer Sheet
4. Cut-to-Size Foam Sheets
Conventional Production of ROHACELL®
6. Sandwich structure
Customer
Page | 18 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Production of ROHACELL® Triple F
1. Liquid Monomer Solution
2. Co-Polymer Sheet
Page | 19 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Production of ROHACELL® Triple F
1. Liquid Monomer Solution
2. Co-Polymer Sheet
3. Co-Polymer Granules
Page | 20 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Production of ROHACELL® Triple F
1. Liquid Monomer Solution
2. Co-Polymer Sheet
3. Co-Polymer Granules
4. Pre-foamed beads
Page | 21 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Production of ROHACELL® Triple F
1. Liquid Monomer Solution
2. Co-Polymer Sheet
3. Co-Polymer Granules
4. Pre-foamed beads
5. IMF Complex Core
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page | 22
Overview ROHACELL® Triple F
Standard production of ROHACELL® foam sheets
The newest product
ROHACELL® Triple F core
Granules Filling
the mold Foaming
(180-250°C) Cooling &
Demolding Ready-to-use
cores
Page 23 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Beads
1. Sandwich Cores Requirements and Overview
2. Manufacturing Process of PMI Rigid Foams
3. Advantages of PMI In-Mold Foaming (IMF)
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 24
Mechanical/Thermal Properties of PMI foam compared to other polymer foams
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 25
Mechanical Properties of conventional PMI foam compared to TripleF
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 26
Properties
of In-Mold Foamed Cores
• Thermal properties as good as convential PMI material
• Mechanical properties slightly lower slight increased density
• Able to withstand fast processes because of high temperature and
compressive creep resistance
• No open pores
less resin up-take, less adhesion but lower weight and class A surface
• Design: High degree of freedom
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Slide 28
Advantages of In-Mold Foaming
Why foaming in a closed Mold?
• Get a final shaped Foam Cores with less production steps and less
material consumption but way faster
• Create Complex Shapes in one step technology
• Utilize high degree of integration to eliminate further assembly steps
• Minimize Waste
• More for Less: Save Time & Money
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Meet Requests for High Volume Applications
Improve your process with ROHACELL® Triple F core
Use the full temperature performance of the resin.
The Tg of ROHACELL® Triple F (~200°C) is significantly higher
than the Tg of all common used resins
0
50
100
150
200
250
50 100 150 200
Gla
ss T
ransit
ion T
em
p. [°
C]
Density [kg/m³]
ROHACELL® Triple F 1-1.5-X A05
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page | 29
Improve your process with ROHACELL® Triple F core
0
1
2
3
4
50 100 150 200
Com
p. Str
ength
[N
/m
m²]
Density [kg/m³]
ROHACELL® Triple F 1-1.5-X A05
A strong, but extremely lightweight core.
Depending on the part / process requirements, cores can be
produced in a customized density range between 70 – 200 kg/m³
or more
0
50
100
150
200
250
50 100 150 200
Gla
ss T
ransit
ion T
em
p. [°
C]
Density [kg/m³]
ROHACELL® Triple F 1-1.5-X A05
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 30
Use the full temperature performance of the resin.
The Tg of ROHACELL® Triple F (~200°C) is significantly higher
than the Tg of all common used resins
Improve your process with ROHACELL® Triple F core
Speed up the curing process.
ROHACELL® Triple F can be processed up to 140°C and up to 6 MPa
0
50
100
150
200
250
50 100 150 200
Gla
ss T
ransit
ion T
em
p. [°
C]
Density [kg/m³]
ROHACELL® Triple F 1-1.5-X A05
Use the full temperature performance of the resin.
The Tg of ROHACELL® Triple F (~200°C) is significantly higher
than the Tg of all commonly used resins
0
1
2
3
4
50 100 150 200
Com
p. Str
ength
[N
/m
m²]
Density [kg/m³]
ROHACELL® Triple F 1-1.5-X A05
A strong, but extremely lightweight core.
Depending on the part / process requirements, cores can be
produced in a customized density range between 70 – 200 kg/m³
or more
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Create geometrically complex parts with very tight tolerances
Tight tolerances
- No need for evacuation due outgassing
- High Surface Finishing due fine cell structure (no potting and sanding is required) and no outgassing
- Helps to reduce manufacturing costs related to time, materials and processing
- The core is directly foamed in a mold and complex geometries can be produced
- Inserts can be easily integrated into the part during the core foaming process
- No outgassing due to residual chemical reactions that can restrict adhesion of layers
Integrated inserts
ROHACELL® Triple F cores are ready to use.
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 32
Conclusion
• Processes need to be faster Materials need to be „faster“
• Sandwich Technology is not cost effective for Large Scale Production
• Sandwich Technology is one of
the best Design Concepts to achieve Weight Reduction
• In-Mold Foamed PMI Triple F is a great opportunity to meet these conditions
High Quality
Time Efficient Process
Cost Efficient Process
Light- weight
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 33
Thank You! Integrate a bit of Magic…
A kind of Magic for complex automotive part design!!!
It’s not Rocket Science…ask our Experts!!!
Page 34