朗盛--楊銳利--Tepex 連續纖維增強熱塑性復合材料及其在量產中的應用.pdf

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1、TEPEX SOLUTIONSThermoplatic Composites in Mass ProductionPol Yang 楊利銳朗盛化學Technical Marketing Manager Tepex Email：Cellphone：137645262342022-03-31PUBLICAgenda1.What is Tepex2.Sustainability3.Production Process4.Applications in Mass production2PUBLICWhat is TepexPUBLICThermoplastic composite solutions

2、since 1997 1997:Formation of Bond-Laminates by Management Buy-Out from DuPont 2003:First Continuous Production line(620 mm)2007/08:2ndand 3rdContinuous Production Line(880 mm)2010:Introduction Hybrid Molding K2010 2011:4thContinuous Production line(1240 mm)2012:100%new ownership:Incorporation to LAN

3、XESS,Business Unit High Performance Materials 2013/14:5thand 6thContinuous Production line(1240 mm)2016:Introduction Hybrid Molding plus IMD w/KURZ et al.K2016 2019:7thand 8thContinuous Production Line(1240 mm)2021:9thContinuous Production Line(1240 mm)Bond-Laminates GmbH-BrilonHistory4Brilon centra

4、ly located in GermanyAirport DUS:160 kmAirport FRA:190 kmPUBLIC Plain,semi-finished product(sheet)based on a thermoplastic polymer(matrix)Reinforcement is a continuous fiber textile(mostly woven fabrics)based on glass,carbon etc.Material is fully impregnated and consolidated fibers are completely co

5、ated with polymer No remaining air inside the material(3%)Thickness of plates:0.1 6.0 mm Production widths:600-1240 mm Fiber volume content:45%-55%Length:adjustable due to continuous processSemi-finished material has final mechanical properties Only heating above the melt temperature Short cycle tim

6、es from sheet to part(60 sec)no chemical reaction while processingvery reproducible process long time stockTepexpropertiesPUBLIC5Tepex:Ready for mass production with leading solution in Continuous Fiber Reinforced Thermoplastics(CFRTP)The continuous lamination process for Tepexproduction is based on

7、 long-term experience in material design and manufacturing of thermoplastic compositesPUBLIC6Mass production:Tepexmanufacturing process with double-belt pressUnwinding of reinforcements and polymersImpregnation and consolidationQA,cutting and packingMaterial combinationTepexprocessingCommissioningTe

8、pex Portfolio Overview7GlassCarbonAramidFlaxPA66PA6PBTPPPA12PPSTPUPCHDPEPLATepex dynalite1 02 RG600(4)/47%weaving style,textile area weight,no.of layers,fiber volume content28 basic polymer-fiber combinations18 basic weave types(Tepex may contain morethan one weave type!)Standard thickness range:0.1

9、 6.0 mm(stepless)Max.sheet width:1240 mm(length:individual/continuous)PUBLICSustainabilityPUBLICSustainability for LANXESS High Performance Materials9Push forward the circular economy Minimize our climate impact Optimize quantity of material needed Reduce wastePUBLICSustainability via Recycled Raw M

10、aterials Production of virgin Carbon fibers consumes a huge amount of energy,costs and resources Tepex enables utilization of recycled carbon fibers ascore layers/surface layers/pure carbon sheetsRecycled Carbon Fibers Recyclate made out of post consumer waste(electronic device casings,toys,safety g

11、oggles,water tower bottles)No significant performance difference between Tepexwith virgin or recyclate matrixRecycled Polymer MatrixPUBLIC10carbon fiber waste(PI)non-woven carbon matpost consumer wastepolymer recyclateSustainability via Bio-Based Raw MaterialsBiobased/Biodegradable polymer matrix(e.

12、g.PA11,PLA)Natural fiber reinforcement(picture:Tepex with flax fiber reinforcement)Weight specific stiffness:PLA/flax PP/GFWeight specific strength:PLA/flax 65%PP/GFApplications possible in all relevant industries(automotive/sports/electronics)PUBLIC11Sustainable Tepex Material Solutions12Polycarbon

13、ate with50%PIR feedstockCarbon Non-Wovenfrom 100%PIR&PCR feedstockFlax fibers100%biobasedreinforcementPLA matrix100%biobased polymer 15%recyclingcontent 50%biobasedcontent 80%recyclingcontentUp to 100%biobased contentPUBLICProduction ProcessPUBLICTepexprocessing in a reproducible process:Forming pre

14、ssure starts from 5 bar,since Tepex materials are already fully impregnatedPUBLIC141minPrinciples of Tepexprocessing4.Remove part3.Forming1.Enter pre-cut part2.Heating(T melting point)Processing of TEPEX Organosheets Handling of inserts Heating above formingtemperature Forming Overmolding Demolding

15、Optional:Decorating(IMD)No reworking necessary Short cycle times(1-2 min)Fully automatedAll in One ShotHybrid Molding+In-Mold Decoration(IMD)15Videos:https:/youtu.be/HJ_N555hWTs/https:/youtu.be/kf0h7nfrF3oPUBLICApplications in Mass productionPUBLICPress release in LANXESS websiteYou can get more inf

16、ormation at LANXESS websiteMore information for TMore information for application press releasehttps:/ information about TepexPUBLIC17Conclusions18Flexible decoration in One-Shot ProcessThin-wall technology for weight savingFunctional integration via hybrid moldingFinished parts“Out-of-the-Mold“Established hybrid molding processOutstanding weight saving potential Consumer electronics Sports AutomotivePUBLICPUBLIC