temperature control in manufacturing self reinforced ... · spe automotive composites conference...

Regloplas AG

David Lowe

Technical Director

Flurhofstrasse 158

CH-9006 St. Gallen

Phone +41-71-282 58 00 Fax +41-71-282 58 40 E-Mail [email protected] Internet www.regloplas.com

Temperature Control in Manufacturing Self Reinforced Polymers (SRP’s)

“A smart way to keep cool”

SPE Automotive Composites Conference & Exhibition (ACCE)

September 11-13, 2013

mailto:[email protected]

mailto:[email protected]

http://www.regloplas.com/

www.regloplas.com

Outline

Who is Regloplas

Temperature Control Developments in ‘Esprit’

Dynamic Heating / Cooling System: Vario

Applications / Customer Benefit

1

2

3

4

5

European Project ‘Esprit’

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

1. Who is Regloplas

Family owned private company

50+ years of experience

70 employees in Switzerland and

> 200 worldwide

Pioneers in temperature control

Wide range of TCU’s and Chillers

from – 8°C up to 350°C

Representatives in over 50

countries

> 7000 TCU’s per year

Regloplas

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

Regloplas customers

| ACCE Sept. 11-13, 2013 | E |


http://dupont.com.ca/

http://www.husky.ca/

http://www.honsel.com/

http://www.hitachi.com/

http://www.ryobi.com/

http://www.toyota.com/

http://delphi.com/

http://www.svensktryckgjutning.se/

http://www.alteams.com/

http://www.alu-laufen.ch/

http://www.bosch.com.br/

http://www.harting.com/en/

http://www.fischerwerke.de/

http://www.tycoelectronics.com/

http://www.geberit.com/

http://www.buhlergroup.com/

http://www.redbull.com/

http://www.dunloptyres.co.uk/home/

http://www.toshiba.com/tai-new/index.jsp

http://www.searchpixie.com/view_image.php?image=hzzaaaapzahpzosysvsyhvsashshaaafaxsfsdsvssspsvhmssssaxzpsaaiaksdaxaazpdaasacaasssvhnamsxaxsxhvaaadsdzdsfsfaxsazphvhcaaaysnzmshaxavsdsssfscsaskscashkscamsahpacaxszdpsaaiaksdaxhvscshsazysssdahsaashnacsnapsnakavsmazsnakaxadamamahszsisishayaaaxakapsmsxasavsiakansiaoakszsnsoayaaahshacsdaksmavszaiamamahszsisishayaaaxakapsmsxsnaaszakamapaoscsisvshazapshacsfsdazacaiaashassasnsdsiscacacscszshscacamasadaxssshamskavsiscshszavshshacsmsysdsnszamansvaoadsismsoskavacakamsdsxsdaosiamsdasaoaksiassoahsfspacaasdscsmshszakanayaoszsyadassnaaadacaasmaisdsnsiamsdapahsdsiacsoahavahshacsdsysmaaszakhshyhohdaxsfszsczozvhyaosyaozmaxaxsfsfaisvsxsdaiahacshznafafaahnaaahassfaxadahadaxaxscsxszsashshayahszaxaxhksdaksasi

http://www.formula1turkiye.com/resim/logo/williams.gif

http://www.honda.co.uk/

http://www.kostal.de/index.html

www.regloplas.com

2. European Project ‘Esprit’

| ACCE Sept. 11-13, 2013 | E |

Goal: Resource-Efficient Self-Reinforced Plastic

Materials and Processing


www.regloplas.com

The Project Partners

The research leading to these results has received funding

from the European Community‘s Seventh Framework

Programme NMP-2007-2.4.1 under grant agreement 214355

(Celstran)

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

Focus: Self Reinforced Polymer (SRP) composites

Fiber and matrix of the same thermoplastic polymer

Lighter than glass reinforced materials

Better impact resistance

More easily recyclable (no mineral fibers to extract)

EC supported project, 3.5 years, finished March 2012

Aim: to produce flowable SRP, reduce plastics usage

Reason: to overcome the manufacturing limitations of

current sheet SRP materials

Molding method: Injection molding, Compression

molding

The Esprit Project Overview


www.regloplas.com

Techniques employed

Reduce melt temperature of matrix and/or increase temperature

stability of reinforcement.

Gives a bigger process window, between the fiber and matrix materials, allowing parts to

be molded without degrading fiber reinforcement

Fiber /matrix combining techniques

Commingling fibres + pultrusion, melt impregnation of matrix into reinforcement. Pellets.

Selective heating of the matrix

To heat just the matrix, not the reinforcement. Microwave and induction heating.

Modified process machinery

Alternative heating methods, tooling modifications, modified pultrusion lines. Control the

temperatures

Injection and Compression molding

Aim to heat and mould the SRP pellets without degradation of the reinforcement

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

Highlights

SRP families tested:

srPA (Nylon), srPET (Polyester), srPO (Polypropylene). srPET proved to be the most

candidate, offering a decent process window and good property improvements

Greatly improved additive dispersion achieved:

(Carbon Nano Tubes in PP), vital for good heating by electromagnetic methods.

Implications in other compounding applications.

Successful injection and compression molding

srPET – 30% improvement in tensile modulus for injection moulded samples

PET/PP – high impact resistance (65kJ/m2 compared to 9kJ/m2 base PP) injection molded

samples

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

The Ultimate Aim

Case Studies

Automotive parts

Sports goods

Lightweight panels

Defence

Luggage

Aerospace

Anything that can be injection or

compression molded in PP, PET

or PA could potentially benefit from

this technology

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

3. Temperature Control Developments in ‘Esprit’:

Temp

Time

Process ‘window’

| ACCE Sept. 11-13, 2013 | E |

Dynamic Heating / Cooling System

Very relevant to Self Reinforced Polymer

(SRP) composite systems

SRPs can be heated in-tool, using textiles

made from yarns of mixed matrix and

reinforcement fibers

Requires a quick heating cycle, a controlled

holding temperature and a quick cooling

cycle


www.regloplas.com


| ACCE Sept. 11-13, 2013 | E |

For the Esprit flowable compounds, the temperature control of the

mould tool is essential:

As the material leaves the injection mold barrel it travels into the tool at high

pressure with the possibility of generating uncontrolled, shear-induced heating

For non-SRP materials this is not a problem

For SRP materials extra heat can lead to reinforcement fiber degradation

Result: accurate, quick, efficient heating and cooling is required

Dynamic heating systems can supply that by using hot and cold circuits

simultaneously


www.regloplas.com


Cavity

part

product

Core part

| ACCE Sept. 11-13, 2013 | E |

For the Esprit Project :

Used in conjunction with appropriately designed tools dynamic heating

systems provide dynamic tool control, allowing the processing of heat-sensitive

materials such as SRP’s

Drawings courtesy of Promolding


www.regloplas.com


| ACCE Sept. 11-13, 2013 | E |

For the natural fibre reinforced products the temperature control of

the mould tool is essential:

Natural fibre reinforced thermoplastics (eg flax or jute fibres in PP or PET) can

be moulded from textiles, direct in the tool.

The fabric is loaded into the tool, then heated and cooled under pressure to

form it. This gives greater conformability.

Speed of heating/cooling is critical to cycle time and mechanical properties

Accuracy of heating is critical to achieve matrix melt without damaging the

natural fibres.

Dynamic heating systems can supply both these requirements by using hot

and cold circuits simultaneously


www.regloplas.com


| ACCE Sept. 11-13, 2013 | E |

Using flax/PP biocomposites:

Used in conjunction with appropriately designed tools dynamic heating

systems provide dynamic tool control, allowing the processing of heat-sensitive

materials such as natural fibres.

Photos courtesy of Composites Evolution


www.regloplas.com

4. Dynamic Heating / Cooling System: Vario

Hot circuit

Cold circuit

Hot circuit

Cold circuit

T [°C]

t [s] tCycle

Temperature Control Unit

mold / cavity

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

| ACCE Sept. 11-13, 2013 | E |


Cold circuit

Cold circuit

T [°C]

t [s] tCycle


mold / cavity


http://www.google.ch/imgres?imgurl=http://www.pcgameshardware.de/screenshots/original/2008/09/strom-signet.jpg&imgrefurl=http://www.pcgameshardware.de/aid,661857/Erstmals-Strom-ueber-148-Kilometer-ohne-Kabel-uebertragen/Technologie/News/bildergalerie/%3Fiid%3D909363%26vollbild&usg=__X425OdIoWxMMfka6j69Kyr0F1Lc=&h=643&w=747&sz=57&hl=de&start=37&um=1&itbs=1&tbnid=_dduuPbDD89rYM:&tbnh=121&tbnw=141&prev=/images%3Fq%3Dstrom%26start%3D20%26um%3D1%26hl%3Dde%26sa%3DN%26rlz%3D1T4ADFA_deCH359CH360%26ndsp%3D20%26tbs%3Disch:1

www.regloplas.com


Water units up to 180°C

Hot oil units up to 300°C

Standard dual or single units

Turn key solution including high

temperature switching valves and

‘energy battery’

Cycle time reduction

Improve surfaces

Eliminate weld lines

Fill difficult cavities faster

Vario details

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com


Unique energy saving concept

Storage of hot and cold energy

Sizing according to application

Automatic filling procedure

Compact design

Faster cycle times possible

Optimized energy balance

Vario ‘energy battery’

Hot circuit

Cold circuit


‚Energy battery‘

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com


| ACCE Sept. 11-13, 2013 | E |

Energy Battery


www.regloplas.com


Oil Temperature Control Unit

Dual unit

70 °C – 280 °C

Cooling and heating process

(Variotherm)

Reduction of cycle time

Online monitoring

Part A

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com


Pressurized Water Control Unit

2 Single units

60 °C – 170 °C

Cooling and heating process

(Variotherm)

Reduction of cycle time

Improved filling and surface

Environmentally friendly

Part B

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

5. Applications: Vario

Weld lines Optical lenses

Shiny surfaces

Parts with thin walls

| ACCE Sept. 11-13, 2013 | E |


http://www.google.ch/imgres?imgurl=http://www.naturalemerygrains.com/images/optical_lens.jpg&imgrefurl=http://www.naturalemerygrains.com/&h=424&w=600&sz=27&tbnid=hjHgXf3IIza5kM:&tbnh=95&tbnw=135&prev=/images%3Fq%3Doptical%2Blenses%2Bpicture&hl=de&usg=__L0MwUHWsmgwqHaEOpcVQk4odCu4=&ei=qDXtS8DOH-SWOKaapa8I&sa=X&oi=image_result&resnum=5&ct=image&ved=0CC4Q9QEwBA

http://www.google.ch/imgres?imgurl=http://thinklaptops.net/wp-content/uploads/2010/01/ASUS-UL80VT-2.jpg&imgrefurl=http://thinklaptops.net/2010/01/asus-ul80vt-review/&h=492&w=496&sz=36&tbnid=22uag_odS__xCM:&tbnh=129&tbnw=130&prev=/images%3Fq%3Dshiny%2Bplastic%2Bsurface%2Bpicture&hl=de&usg=__2Y6MBcxBcFDbK97DAMtszMtJF68=&ei=yDjtS6axDc6POLbY5JgI&sa=X&oi=image_result&resnum=3&ct=image&ved=0CCEQ9QEwAg

http://www.google.ch/imgres?imgurl=http://www.elektroradar.de/WebRoot/Store/Shops/ElektroRadar/Products/Images/31/0458531/661780_0458531.jpg&imgrefurl=http://www.preisroboter.de/search.php%3Fsearch%3Dphoenix%2Bcontact%2Bpik%2B4-l%252Fl%26start%3D30%26shift%3D0%26sortmode%3D0%26min%3D%26max%3D&usg=__UGLzqSzJcKag7vtxjZO0vQkEpB8=&h=353&w=463&sz=28&hl=de&start=75&um=1&itbs=1&tbnid=dOhzF1-SEF1JMM:&tbnh=98&tbnw=128&prev=/images%3Fq%3Dklemme%2Bbild%2Belectronic%26start%3D60%26um%3D1%26hl%3Dde%26sa%3DN%26rlz%3D1T4ADFA_deCH359CH360%26ndsp%3D20%26tbs%3Disch:1

www.regloplas.com

Applications: Vario

Composites/SRP‘s

Dual material components

Micromolding

| ACCE Sept. 11-13, 2013 | E |


http://www.google.ch/imgres?imgurl=http://data.motor-talk.de/data/galleries/90882/12974/rueckleuchte.jpg&imgrefurl=http://www.motor-talk.de/blogs/olli-the-driver/probefahrt-im-b180-cdi-ein-auto-weniger-auf-der-liste-t1780124.html&usg=__wiwE4Se8nCeQQxI30meAbWFc4Ow=&h=682&w=1024&sz=150&hl=de&start=150&um=1&itbs=1&tbnid=4kTHk9nt1EMpeM:&tbnh=100&tbnw=150&prev=/images%3Fq%3Dbild%2Brueckleuchte%2Bauto%26start%3D140%26um%3D1%26hl%3Dde%26sa%3DN%26rlz%3D1T4ADFA_deCH359CH360%26ndsp%3D20%26tbs%3Disch:1

http://www.google.ch/imgres?imgurl=http://www.steuer-buero.biz/img/lupe.jpg&imgrefurl=http://www.steuer-buero.biz/wirtschaftspruefung01.htm&usg=__t0KO6N2bY_CkvlAGmdtyqxjJk0Q=&h=350&w=278&sz=9&hl=de&start=3&um=1&itbs=1&tbnid=-j6kw_ayIaWI6M:&tbnh=120&tbnw=95&prev=/images%3Fq%3Dlupe%26um%3D1%26hl%3Dde%26rlz%3D1T4ADFA_deCH359CH360%26tbs%3Disch:1

http://www.google.ch/imgres?imgurl=http://www.micropep.com/images/micro_stamped_1.jpg&imgrefurl=http://www.micropep.com/cleanroom.php&usg=__eOGskbmxAO3AgEEYEMgR1PvwPPk=&h=200&w=300&sz=46&hl=de&start=6&um=1&itbs=1&tbnid=pIz7NHHnY2hMNM:&tbnh=77&tbnw=116&prev=/images%3Fq%3Dmicromolding%26um%3D1%26hl%3Dde%26rlz%3D1T4ADFA_deCH359CH360%26tbs%3Disch:1

www.regloplas.com

Customer benefit

Quality improvement

Quality consistency

Cycle time optimization

Lower running costs

(energy, life time die, oil,…)

Environmentally friendly

Less cost per part

ROI

| ACCE Sept. 11-13, 2013 | E |


www.regloplas.com

Thanks for your attention!

Q+A‘s

“A smart way to keep cool”

| ACCE Sept. 11-13, 2013 | E |


temperature control in manufacturing self reinforced ... · spe automotive composites conference...

Documents