Complex shaped PMI Foam Cores
for highly efficient FRP Composite
ROHACELL®
Triple
F
Sandwich Fabrication for low to
- A Novel Particle Foam
high volume applications
SAMPE
Brazil Conference 2015
tesDr. Kay
22nd October 2015, Sao Jose dos Campos, Brazil
Fabio Tufano
M. Alexander Roth, Dr.-Ing.
Technical Sales & New Business
Development South America
Evonik Degussa Brasil Ltda.
Director ROHACELL® Americas &
Vice President
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
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.
Fibers, e. g. CF, GF
Resin, e. g. EP
FRP Face Sheet
Core, e. g. PMI-Foam
Resin, e. g. EP
Fibers, e. g. CF, GF
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 3
The Sandwich Effect
Sandwich Structures are very suitable for
bending & axial compressive loaded parts
to increase:
 Bending stiffness and strength
 Buckling and crash performance
Lightest Solution!
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
Slide 4
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
Slide 5
Requirements for Sandwich Cores
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.
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.
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Page 6
Biggest Hurdle for more Composites:
Manufacturing Costs
Requirements from OEMs: “Competitive costs for composites”
Overall cost
100 %
0%
current
composite costs
requested
costs
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 7
Biggest Hurdle for more Composites:
Manufacturing Costs
Requirements from OEMs: “Competitive costs for composites”
Overall cost
100 %
Production process has
the biggest potential to
decrease costs!
0%
current
composite costs
requested
costs
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
Production Processes
Trend toward mass production
Production
process
HP-RTM,
Press Moulding
Fast
(Prepregs, Organosheets,
Dry Fabrics/Liquid Resins,
Foam Cores)
Hand Lamination,
AutoclaveTechnology
Slow
(Prepreg,
Honeycomb)
Number of Parts
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Page 9
Production Processes
Dry-Compression
Prepreg
Core
180 °C
IR
Press
IR
Press
Wet-Compression
Epoxy
140 °C
IR
Press
IR
Press
Core
shorter production cycle time of composite parts
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Page 10
Production Processes
Textiles
Finished part
Pressure
Core
Epoxy
Pre-formed
Sandwich
Positioning
in mold
Injection
Vacuum
(optional)
A fast curing process requires a core to withstand:
• temperatures of 80-140°C
• pressures of 20-80 bars
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
• Low Weight = Low Density
• Low Uptake of Resin
• Adhesion to Cover Layers
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
Medley of a few Applications with
ROHACELL® inside
Radome & Antennas
Aerospace
Automotive
Consumer Electronics
Ship Building
Wind Energy
Medical
Sports
Source of images: The Use of PMI Foams for Sandwich Applications in the Aerospace Industry, 2 nd 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®
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 16
Conventional Production of ROHACELL®
4. Cut-to-Size Foam Sheets
3. Raw Foam Block
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 17
Conventional Production of ROHACELL®
6. Sandwich structure
Customer
5. Net-Shaped cores
4. Cut-to-Size Foam Sheets
3. Raw Foam Block
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 18
Production of ROHACELL® Triple F
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 19
Production of ROHACELL® Triple F
3. Co-Polymer Granules
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 20
Production of ROHACELL® Triple F
4. Pre-foamed beads
3. Co-Polymer Granules
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 21
Production of ROHACELL® Triple F
4. Pre-foamed beads
3. Co-Polymer Granules
5. IMF Complex Core
2. Co-Polymer Sheet
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
1. Liquid Monomer Solution
Page | 22
Overview ROHACELL® Triple F
Standard production of ROHACELL® foam sheets
The newest product
ROHACELL® Triple F core
Granules
Beads
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Filling
the mold
Foaming
(180-250°C)
Cooling &
Demolding
Ready-to-use
cores
Page 23
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
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
Meet Requests for High Volume Applications
SAMPE Brazil Conference 2015, 22nd October 2015, Sao Jose dos Campos, Brazil
Slide 28
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
Glass Transition Temp. [°C]
250
200
150
100
50
ROHACELL® Triple F 1-1.5-X A05
0
50
100
150
200
Density [kg/m³]
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
Page | 29
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
Glass Transition Temp. [°C]
250
200
150
100
50
ROHACELL® Triple F 1-1.5-X A05
0
50
100
150
200
Density [kg/m³]
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
Comp. Strength [N/mm²]
4
3
2
1
0
ROHACELL® Triple F 1-1.5-X A05
50
100
Density [kg/m³]
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
150
200
Page 30
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 commonly used resins
Glass Transition Temp. [°C]
250
200
150
100
50
ROHACELL® Triple F 1-1.5-X A05
0
50
100
150
200
Density [kg/m³]
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
Comp. Strength [N/mm²]
4
3
2
1
0
ROHACELL® Triple F 1-1.5-X A05
50
100
Density [kg/m³]
Speed up the curing process.
ROHACELL® Triple F can be processed up to 140°C and up to 6 MPa
SAMPE Brazil Conference 2015, 22nd October, São José dos Campos
150
200
Create geometrically complex parts
with very 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
Tight tolerances
ROHACELL® Triple F cores are ready to use.
Integrated inserts
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
•
Time
Efficient
Process
Cost
Efficient
Process
High
Quality
Lightweight
In-Mold Foamed PMI Triple F
is a great opportunity to meet
these conditions
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
Slide 35