Manufacturing composites with new injection … · 1 Peter Egger, 10.10.2013 Composite Technologies...

1Peter Egger, 10.10.2013

Composite Technologies

ENGEL steht für: NEU

Manufacturing composites with new injectionmoulding technologies

Peter Egger

Inject the future.



Trend for light and strong parts!

> Electro mobility> CO2 reduction

Challenges for using composites

> Material prices> Economic processes for mass production> Too less knowhow in composites technologies



Combining two different worlds!

> Injection molding• High productivity• Fully automated processes

> Composite technologies• Strong parts• Low quantities• Manually driven

For speaking the same language……

Foundation of Center for Lightweight Composite Technologies



Composite key technologies



Working with thermoplastic fabrics - organomelt

> Woven and non woven fabrics, or unidirectional reinforcements> Fully impregnated and consolidated

heating, forming, back molding



Composites for brake pedal

Advantage: integrating of functions> 50% lighter than solution in steel

Composite Innovations Award 2011Foto: ZF Friedrichshafen AG



> Force orientated> Optimized use of material

• Building up of layers• Preforming and backmolding

ǁ

E >> Eǁ

Choosing UD-tapes



2500 V-DUO

Ultralitec – demonstrator part



Why using prepregs?

> Cost for prepregs> Energy input for deconsolidation

> Ideal would be• Force orientated lay up with dry fibre

structures• Impregnation by back molding• „One shot – one part“!

Viscosity plays against!


Composite TechnologiesEinfluss der Viscosity

0,001

0,01

0,1

1

10

100

1000

10000

100000

Honey at room temperature

Engine oil at roomtemperature

Thermoset resins at processing temperatures

Vis

cosi

ty (P

a*s)

Blood at room temperature

Monomers like Caprolactam

Thermoplastics at processing temperatures



High pressure - Resin Transfer Molding

Composites with epoxy-resins or polyurethanes

> Impregnation of textile fabrics with thermosets• Stacking

• Preforming

• Lay up

• Impregnation

• Curing under temperature

• Demolding & cutting



Composites with thermosets

> Force orientated lay up of fibrestructures

> Good impregnation> Low shrinkage> High mechancis

Long curing times> No welding> Recycling difficult

Benteler SGL



Reactive thermoplastic resins?

Insitu – polymerisation (insitu: latin for „then and there“)> Anionic polymerisation of caprolactam to Polyamid6

• Monomers with very low viscosity• Preparation with activator and catalysator in HP-RTM-unit• Infiltration of textiles • Curing (polymerisation) under temperature

+activator+catalysator

T = 150°C



Cast polyamid

> For thick walled preproducts> Very high impact properties

TECARIM PA 6G copolymer (Nyrim)


Composite TechnologiesHD-RTM thermoplastic: insitu Polymerisation (anionic)



Reactive injection molding

> Injection molding technology for HD-RTM

Insitu-Prototyp

Caprolactam+ Aktivator

Caprolactam+ Katalysator

Mixing head


Composite TechnologiesDevelopment Live!

Infiltration cutting In-situ-insertPreforming

In-situ-Process



The best of both worlds…..

Reactive thermoplastic resins> Force orientated lay up like with thermosets> Low pressure impregnation> Fully thermoplastic solution

• Welding• Functionalisation• Recycling

> In development• Process technologies• Process times



Machine technologies for composite processing

> Horizontal clamp units• Easy to automate• Flexibel system also for other injection molding technologies• Holding of inserts as challenging factor



Lab unit for development of large scalecomposite production

> Verticale Insert-clamping units• 4000 kN und 1000 kN

> 4-Station rotary table> Multicomponent injection

molding, injection compressionmolding, foaming



New vertical concepts for composite processing

> 2500 V-DUO> Proven 2-platen

clamping unitin new verticaldesign



Insitu Polymerisation

Tape Technology

Organomelt

HP-RTMNew Processes

New Machines

New Materials

Com

bine

d De

velo

pmen

t

K‘2013 !

K‘2013 !

K‘2013 !



Center for lightweight composite technologies

Composite technologies needcomposite development!

> Establishing network for compositetechnologies

> Developement of new processes> Integration of reaction technologies> Providing system solutions> Lab for internal and external trials



Thank you!

Mail: [email protected]: 0043/50 620 - 4670

Manufacturing composites with new injection … · 1 Peter Egger, 10.10.2013 Composite Technologies...

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