1. Introduction of Toray and Zoltek 2. Automotive ... · Sheet Moulding Compound . Confidential 20...
Transcript of 1. Introduction of Toray and Zoltek 2. Automotive ... · Sheet Moulding Compound . Confidential 20...
Confidential 1
Outline
1. Introduction of Toray and Zoltek
2. Automotive Applications
a) Prepreg Application
b) HP RTM Application
c) Automated Fiber Placement
d) Sheet Moulding Compound
e) Thermoplastic Composites
3. Summary
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Toray Group Corporate Profile
§ Company Name: Toray Industries, Inc.
§ Founded : January 1926
§ Capital Stock : 148 billion Yen
§ Number of Subsidiaries & Affiliates : 254 (Japanese 100, Overseas 154)
§ Employees :
§ Toray 7,223
§ Consolidated basis 45,839
President Akihiro Nikkaku
(as of March 31, 2016)
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Zoltek’s Corporate Profile
§ Company Name: Zoltek, Inc.
§ Founded: 1975
§ Headquarters: St. Louis,MO, United States
§ Representative: Yoshihiro Takeuchi (CEO) § Group Companies: 3 Consolidated Subsidiaries
§ Employees: 2,500
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Zoltek’s Operations Footprint
St. Charles, MO • Chopped Fiber • Milled Fiber • Technical Fiber • Aircraft Brake Fibers St. Peters, MO • Pultrusion • R&D • Milled fibers
Nyergesujfalu, Hungary • Precursor • Carbon Fiber • Technical Fiber • Fabrics / Yarns • Pultrusion • Chopped Fiber
Guadalajara, Mexico • Precursor • Carbon Fiber
Salt Lake City, UT Entec Composite Machines
St. Louis, MO Zoltek Corporate
Headquarters
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Zoltek PX35 50k large tow carbon fiber
Intermediate Products
Zoltek PAN Precursor
Zoltek™ PX35 Carbon Fiber
Manufactured In One Location
CONSOLIDATED SUPPLY CHAIN
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Zoltek™ PX35 Continuous Tow Carbon Fiber Zoltek PX35 Standard Modulus, Large Tow Carbon Fiber
Advantages Cost Effective, Stable Supply, Stable Pricing Main Products Zoltek PX35 Carbon Fiber, Oxidized PAN Fibers
Zoltek Intermediate Products
Chopped & Milled Fibers Unidirectional Fabrics Pultruded Profiles Thermoplastic Tapes (Developmental)
Partner Intermediate Products
Multiaxial Fabrics Carbon SMC Prepregs Thermoplastic Compounds/Tapes
Applications Wind Turbine Blades Automotive Structural Parts Offshore Drilling/Buoyancy Applications Infrastructure/Civil Engineering High Pressure Vessels
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Key Differences in Business Strategy
1. Lowest-cost producer
– Textile type precursor – Lowest capital investment
required in the industry
2. Supply commitment
– Modular, in-house design for carbon fiber lines
– 6 month capacity installation – Low investment cost enables
support of high-growth
3. Sustainable pricing
– Stable pricing for long-term commitment by strong cost competitiveness
4. Applications development
– Focus on high volume emerging commercial markets
– Specially designed precursor – High capital requirements to
build for variety of products
– Standard carbon fiber lines designed by Toray
– 18-24 month capacity installation
– High investment costs, more conservative approach
– Value adding pricing with higher performance
– Focus on high performance & new value added markets
ZOLTEK TORAY
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Carbon Fiber Value Chain Carbon Fiber Production Dry Process Composite Part
Fabrication Customer
Application Wetting Process
Weaving
Braiding
CF Tow
Chopped & Milled CF
Thermoplastic Compounding
Infusion / RTM
Autoclave / Vacuum /
Compression Molded
Filament Winding
Pultrusion / Pull-winding
Injection / Compression
Molding
Composite Parts
Precursor Production
PAN Precursor
Prepreg
UD Fabrics
Multi-axial
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2. Automotive Applications
Pultrusion - Door Sill/Rocker
Panel - Door Inner
Support - Diagonal Engine
Strap
SMC - Hood Inner - Door Inner - Liftgate/Decklid
Inner - Load Floors
Fabric/RTM - Rear Seat Wall - Roof - B-Pillar - Load Floors - Crash Tubes
Prepreg - Hood - Trunk Lid - Roof
Thermoplastics - Trunk Lid Inner - Door Inner - B-Pillars - Seat Structures - Load Floors - Various Interiors Parts - Crash Tubes
Vehicle Class Exo.c Luxury Premium Standard Mid-‐Sized
SMC
RTM/ LCM
Prepreg
Pultrusion
Thermoplas.cs Large Future Growth Targeted Starting in 2025SOP Vehicles
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2. Automotive Applications Prepreg
Advantages (+) Limita.ons (-‐)
Low entry costs/ low capex High Material Costs
High performance Low material flexibility
Class A surface High Scrap rate due to cu?ng out
Compete w/ Steel & AL
Composite Design Rules
Source: Hexion
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2. Automotive Applications Prepreg
Tier 1
Tier 2
Cadillac ATS-V and CTS-V Hood Source: Dr. Laux: Class A Compression-Molded Carbon-Fiber Hood, VDI Tagung Mannheim March 9-10, 2016; Mannheim, Germany
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2. Automotive Applications
HP RTM
Advantages (+) Limita.ons (-‐)
High Material Flexibility High Capex
High performance High Scrap rate due to cu?ng out
Class A surface Preforming
Compete w/ Steel & AL
Composite Design Rules
Source: Hexion
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2. Automotive Applications
HP RTM
Tier 1
Tier 2
Roof Frame developed by Plasan Carbon Composites
• Replacement of Magnesium die cast part • Structural application • Lighter than metal solution • Cycle time in minutes
OEM
Source: J. Stargaard: From hours per part to parts per hour; ACCE Conference; September 7-9, 2016; Novi, MI, USA
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2. Automotive Applications Automated
Fiber Placement
Advantages (+) Limita.ons (-‐)
High Material Flexibility High Capex
High performance
Reduced Scrap
Compete w/ Steel & AL
Composite Design Rules
Fast Cycle Times
Part (blue)
Scrap/ Cut Out (grey)
Fabric Based Process
Part (blue)
Scrap/ Cut Out (grey)
Fiber or Tape Placement Process
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Voith’s Direct Processing Technology: • Directly from raw material to fully assembled part • By-passing of value steps in supply chain • Minimizing production scrap rates • Fully automated manufacturing process
dedicated to Automotive High Volume Serial supply
• Based on large tow carbon fiber Zoltek PX35
Company: Voith Group Revenue in 2015: 4,3 Billion€ Employees: 19.000 R&D Ratio: 4,9% Composite Technologies Voith Composites, Garching/ Germany
Fully Integrated and Automated Direct Process at Voith
Carbon Fiber Tow
Tow Spreading
Tow Placement & Stacking
3d preforming HP RTM Trimming Assembly Component
2. Automotive Applications
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Costs per kg assembled part
Characteristics of Voith’s direct fiber placement process
Performance of Tape Laying Process
Part size: 1m x 1m Plies: 6 gsm/ ply: 200gsm Max. Part size: 3m x 3m Min. Part size: 0.1m x 0.1m
Source: Voith Composites
Source: Voith Composites Zoltek PX35
2. Automotive Applications
Use of Process
“Audi AG has placed an order with Voith for the high-‐volume
produc.on of a CFRP component for a future Audi model. Voith and Audi will
jointly prepare the manufacturing ramp-‐up for the
CFRP component.” Source (June 5, 2015): hSp://
www.jeccomposites.com/knowledge/internaVonal-‐composites-‐news/voith-‐
receives-‐order-‐high-‐volume-‐producVon-‐cfrp-‐components
Source: Voith Composites
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2. Automotive Applications Sheet
Moulding Compound
Advantages (+) Limita.ons (-‐)
Low Scrap High Capex
Design Freedom
Fast Cyles
Fully Automated
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Standard PX35 50k tow
• Large tow with 50k filaments • Suitable for SMC • Available with several sizings for
Polyester resin, Epoxy resin, Vinylester resin
KASSEN PX35 KS tow
• Based on Zoltek PX35 50k tow • Falls apart into 3k strands after
chopping • Can be processed in standard SMC
sheet machines
2. Automotive Applications Sheet
Moulding Compound
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・ Slit PX35 KS fiber -‐ Higher dispersibility like small tow -‐ Higher Mechanical Proper.es, & Lower Varia.on
ZOLTEKTM Slit Fiber PX35 KS for Sheet Molding Compound
2. Automotive Applications Sheet
Moulding Compound
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2. Automotive Applications Thermoplastic Composites
Advantages (+) Limita.ons (-‐)
Low Scrap Medium Performance
Design Freedom
Fast Cyles
Globally Established
High Variety of Resins
Sizings for Thermoplastic
Resins Polyamide
High Temperature Resins
Polypropylene
Carbon Fiber Format
Tow
Fabrics
Chopped
Milled
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2. Automotive Applications Thermoplastic Composites
Polypropylene
Tensile Properties
Why CFR-PP? • It has densities 20%-30% lower than SMC and GFR-
PA • Its rigidity is 2 times that of conditioned GFR-PA • It has outstanding resistance to water absorption and
hydrolysis • Its lower densities and higher rigidity combine to
offer up to 50% weight reductions • Lower residual monomer in PP – a plus for auto
interiors
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Thermoplastic Composites Thermoplastic Composites
Thermoplastic Tapes
Status: Experimental Grade Carbon Fiber: Zoltek PX35-05015W-61 Resin: Polyamide 6 Fiber content: 150gsm Resin content: 90gsm
Property (Fiber content: 50%vol) Value
Tensile Modulus (0°) 115GPa
Tensile Modulus (90°) 5.4GPa
Tensile Strength (0°) 1135MPa
Tensile Strength (90°) 30MPa
Flexural Modulus (0°) 110GPa
Flexural Modulus (90°) 4.7GPa
Flexural Strength (0°) 990MPa
Flexural Strength (90°) 49MPa
Shear Modulus 1465MPa
Shear Strength 31MPa
Trials run at and mechanical characterization performed by CETEX GmbH, Chemnitz, Germany
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3. Summary
• Carbon Fiber is ready for high volume automotive Applications
• Large tow carbon fiber is available in large quantities at the required price
• CFRP parts are in serial production
• Prepreg
• Pultrusion
• Future CFRP applications in automotive serial production
• HP RTM Application
• Automated Fiber Placement
• Sheet Moulding Compound
• Thermoplastic Composites