New developments for mass production of epoxy … production of epoxy automotive composites ......

New developments for

mass production of epoxy

automotive composites Alex Schmidt

Senior Development Engineer

Composites Europe 1

Composites Europe Forum 2016

1 DECEMBER 2016

…at a glance

$3.6 billion

4300 people

60 production sites

Hexion is a Specialty Chemicals Company with a

leading position in the development and production of

systems, products and services for

Weight reduction and Protection in the

Energy, Transportation and Construction markets

Technology Platforms

Epoxy

Phenolics

Versatics

Formaldehyde

Automotive

Lightweight Composites

Under The Hood parts

Suspension

Braking

Rubber goods

Coatings E-Coat to Clear Coat

Composites Europe 2 1 December 2016

Global Leadership Positions Across a Broad Range of

Technologies and Industries with Blue-Chip Customers

Oilfield Proppant Resins Global

Phenolic Specialty Resins Global

Versatic™ Acids & Derivatives

Global

Forest Product Resins Global

Epoxy Resins Global

Specialty Epoxy

Base Epoxy

Leading Market Positions Customer Base

LEADING MARKET POSITIONS IN MORE THAN 80% OF ITS REVENUE BASE

Interior Parts


http://www.sec.gov/

http://www.masisa.com/exp/eng/Default.html

The car industry implements light weight

solutions to comply with CO2 emission and

fuel consumption reduction legislation


Composite technology developments

enable mass production of automotive parts


Composite technology innovations

offer you cost-efficient light-weighting

Composites Europe 6

Composites:

Offer highest weight reduction opportunities in automotive applications

Innovative processing technologies:

Enable mass production of automotive parts

1 December 2016

Carbon Fibre Reinforced Plastics (CFRP)

has the highest weight reduction potential

Composites Europe 7

Sources: McKinsey Lightweight, heavy impact 2012;

Roland-Berger, 2012

100

80

80

60

50

0 20 40 60 80 100

Steel

HSS

Plastics

Aluminum

Carbon fiber

Part weight | % of steel

Typical cost build-up

50% material • 40 - 45% carbon fiber

• 5 - 10% resin

50% processing • Quicker curing matrix

• Process optimization

• Near-end-contoured preforms

• Automation

1 December 2016

The BMW 7-Series Carbon Core illustrates

body-in-white mixed material use

8

BMW 7-Series Various CFRP parts e.g. roof arc and tunnel reinforcement BMW SOP: 2015

Composites Europe

Source: BMW Group

Benefits • 40 kg weight reduction vs. steel in the Carbon Core body structure

• Fast curing cycle enabled by Hexion’s latest resin technology

• Multi material mix – engineered to performance

1 December 2016

Composite technology innovations offer

you cost-efficient light-weighting

Composites Europe 9

Composites:

Offer highest weight reduction opportunities in automotive applications

Innovative processing technologies:

Enable mass production of automotive parts

1 December 2016

Optimum CFRP performance and cost

is complemented with good design

Composites Europe 10

Process Capability

For OEM Industrialization

Materials Partnerships

Through Value Chain

Optimum

Performance

and Cost

Liquid resins

Epoxy Resins:

Hot melts

Perform Binders

Mould Release Agents

Prototyping systems

Phenolic Engineering Thermosets

Injection Moulding LCM Compression Moulding Prepreg HP-RTM

Performing SMC FiWi Towpreg

Equipment suppliers

Part Design and Modeling

Process Design and Modeling

Tool Building

Reinforcements

1 December 2016

Epoxy CFRP with Resin Transfer Moulding

(RTM) technology for structural applications

11 Composites Europe

Audi R8 Coupe and Lamborghini Huracan (MSS Platform)

CFRP Transmission Tunnel

ACE

EPIKOTE™ Resin TRAC 06150/

EPIKURE™ Curing Agent TRAC 06150

Benefits • 30% lighter than aluminium

• Short cycle time

1 December 2016

RTM technology enables fast production

of highly complex structural parts


Mould closing and resin injection • Thermal latency

• Low viscosity

• Rapid fibre wetting

Curing • Fast conversion

• Isothermal

• Low exotherm

Opening and de-moulding • Easy de-moulding

• Part quality

• Reproducibility

Lay-up binder stabilized fabric

Heating and some pressure • Fast handling

• Textile stability

• Controlled permeability

1 December 2016

Epoxy binders address preforming

challenges in fast RTM


Benefits

• Faster handling/positioning

• Controlled permeability and lay-up definition

• Textile stability at mould temperature

1 December 2016

The part size and equipment determine

the material processing window


Part

0

1000

2000

3000

4000

5000

6000

7000

0 20 40 60 80 100 120

Resin Injection rate (g / sec)

60 g/s

Injection time (sec)

Resin Shot weight (g)

EP TRAC 06170

EK TRAC 06170

33 sec

EP TRAC 06150

EK TRAC 06165

45 sec

EP TRAC 06150

EK TRAC 06150

95 sec

80 g/s 100 g/s

80% of

Moulded parts

Equipment

Material

1 December 2016

Epoxy CFRP with RTM & LCM technology

for structural applications


BMW 7-Series

CFRP roof arc

EP TRAC 06000/

EK TRAC 06130

Benefits

• Local reinforcement enhances

torsional stiffness

• Fast curing cycle with LCM

BMW 7-Series

CFRP tunnel reinforcement

EP TRAC 06000/

EK TRAC 06130

Benefits

• Designed to the shape of the car body

• Fast curing cycle with HP-RTM

• Outstanding weight / performance ratio

1 December 2016

LCM: Preforming is simplified and direct

liquid resin application shortens the cycle time


Transfer wet lay-up into mould

Curing

• Controlled viscosity built

• Fast conversion

• Low exotherm

Opening and de-moulding • Easy de-moulding

Lay-up dry fabrics

Liquid resin application

• Tailorable latency

1 December 2016

Liquid Compression Molding (LCM) is cost

attractive with increasing complexity of parts


Low Part complexity

Cost

Pre

form

requirem

ents

Pro

cess c

om

ple

xity

High

High

RTM

LCM

1 December 2016

Part to part cycle times of 50 seconds have

been demonstrated with LCM

ACCE

7 Sept. 2016 18

Press closing

Impregnation

Curing

Press opening

Part to part cycle times of 50 seconds have

been demonstrated with LCM


HexionLCMProcess_8282015.mp4

Epoxy CFRP with RTM & SMC technology

for semi-structural applications


JEC Award Winning CFRP Decklid Demonstrator

Continental Structural Plastics (CSP)

EP TRAC 06170/EK TRAC 06170

Benefits • Weight reduction of 13% compared to aluminum

• Short cycle time

• Combined material technologies: CF RTM inner and SMC outer

1 December 2016

Improved cost efficiency of SMC technology

net shape moulding without preforming


SMC Cutting & moulding • Lower scrap rate than RTM

• Hybrid reinforcement

• Functionalization

Pressing • Short in mould cycle times

• Controlled flow

• Netshape

Part de-moulding • Low shrinkage

• High strength/modulus

• Reproducibility

Component mixing

SMC compounding • Good fibre wetting

• Potential use recycled fibre

• Fast maturation

• Low Viscosity

• No VOC (styrene free)

1 December 2016

EPIKOTE™ Resin Systems have

benefits in SMC


Epoxy benefits versus

vinylesters and unsatured

polyesters

• No VOC and styrene free

• Inherently low shrinkage

• Better mechanical strength properties

• Good adhesion to glass and carbon fibre

• Compatible with other material Epoxy

technologies

• Higher Tg

• Higher fatigue/durability performance

1 December 2016

Epoxy CFRP with prepreg technology

for semi-structural applications


Forward Light Holders

CMP GmbH - UBC GmbH

EP TRAC 06425/

EK TRAC 06465

Mini Front Wings

CMP GmbH - UBC GmbH

EP TRAC 06425/

EK TRAC 06465

Performance Benefits • Lightweight versus steel

• Short cycle time (90 sec or 3–5 min)

• High performance

• High Tg

Processing Benefits

• Long shelf life at room temperature

• Easy and versatile moulding

• In house prepreg as viable approach

to further reduce cost

1 December 2016

High mechanical performance is

achieved with prepreg technology


Cutting & moulding • Low scrap rate

• Hybrid reinforcement

• Functionalization

Pressing • Short in mould cycle times

• Controlled flow

• Netshape

Part de-moulding • Low shrinkage

• Mechanical performance

• Reproducibility

Impregnation

Fibre or prepreg placement • Easy fiber positioning

• Stable band width

• Good fiber wetting

• Low Viscosity

• No VOC

• No preforming

1 December 2016

25

Complex structural components can be

manufactured with prepreg technology

Epoxy CFRP

for exterior applications

JEC World 2016 26

Porsche 911 GT3

Door

Benteler SGL

SOP: 2013

Benefits

• Lightweight

• Lower center of gravity

• Class A appearance

• Hot wet resistance

• Carbon fiber aesthetic / styling option

BMW

Roof Panel

M3, M6

SOP: 2004

Lamborghini Aventador

Bonnet

ACE

SOP: 2011

8 March 2016

Epoxy CFRP

for suspension applications

JEC World 2016 27

Mercedes Sprinter

Leaf Spring

IFC Composites

SOP: 2006 & 2013

Benefits

• Weight reduction 4.4 kg

• Smoother riding with improved precision

• Failsafe design

• Inherently corrosion-free

• Low carbon footprint

Audi A6 Avant 2.0 TDI Ultra

Coil Spring

S.ara Composites – SOGEFI

SOP: 2014

Benefits

• Weight reduction of 14 kg

• High volume capable

• Improved vehicle NVH

• Corrosion resistance

• Hot-wet resistance

8 March 2016

Key takeaways


Epoxy Fibre Reinforced Composites:

Highest weight saving potentials

New generation resin systems:

Faster cure cycles, easier demoulding and more process versatility

Design and consolidation of component:

Will continue to decrease cost per kg weight saving

1 December 2016

DISCLAIMER

The information provided herein was believed by Hexion Inc. and its affiliated companies ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be

reliable, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safe

handling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and conditions of

sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANY PURPOSE

OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothing contained herein

constitutes an offer for the sale of any product.

© 2015 Hexion Inc. All rights reserved.

® and ™ denote trademarks owned or licensed by Hexion Inc.

Thank you!


Innovation Built on Collaboration

Your Partner in Composite Resin solutions

Alex Schmidt

Senior Development Engineer

[email protected]

1 December 2016

New developments for mass production of epoxy … production of epoxy automotive composites ......

Documents

Transcript of New developments for mass production of epoxy … production of epoxy automotive composites ......