CFRP夾層結構的泡沫芯（23頁）.pptx

1、Foam core of sandwich structure in CFRPQianwen Kong,HP Products for the Composite Industry,ROHACELL Foam for sandwich structures,VESTAKEEP VESTAMID,TROGAMIDVESTAMID HTplus PEEK,(Co)PA12 and PPA resin for thermoplastic matrices,VESTAMID PA powders as toughener for epoxyP84 PI Powder as BMI resin modi

2、fier,Slide|2,Slide|3,ROHACELL,ROHACELL Sandwich increases stiffness and is Key to Weight Saving,bending stiffness bending strength weight,monolithic,sandwich,sandwich,Why use sandwich construction?The sandwich principle,high modulus and can carry tensile and compression loads,low density and can car

3、ry shear loads,Page 4,ROHACELL industry breakdown,Aircraft,Lifestyle*,Auto,Wind,*Lifestyle:sports equipment,medical tables,electronics,radomes,ROHACELL New Innovations,Page|5,Sandwich construction leads to the lightest available final parts.,Four material options:,Dimensioning load case:Boundary con

4、ditions on hinges and lockForce couple of F=100 N on edges of lidMaximum deflection from all load casesGlazing has a major effect on torsional stiffness,Load case:“Torsion”,Page|6,Torsion,ROHACELL New Innovations,Page|7,It can also offer significant cost reduction in mass production.,Page|8,Requirem

5、ents from OEMs:“Competitive costs for composites”,Overall cost,currentcomposite costs,requestedcosts,100%,Production process has the biggest potential to decrease costs!,0%,Slide|9,1.Liquid Solution,2.Co-Polymer Sheet=Pre-Product,3.Raw Foam Block,4.Cut-to-Size Foam Sheets,5.Net-shaped cores,Polymeth

6、acrylimid(PMI)foamROHACELL for sandwich core,6.Sandwich(customer),Basic Monomers:Methacrylic Acid/Methacrylonitrile,ROHACELL New Innovations,Page|10,Mass production with ROHACELL products New thermo-shaping technique Innovative“In Mold Foaming”,ROHACELL New Innovations,Page|11,New thermo-shaping tec

7、hnique,Shorten the cycle time for shaping,With the new thermo-shaping technique,the process is now shortened to 2 min making ROHACELL ideal for mass production.,Thermo-shaping ROHACELL has been state of the art technology for more than 30 years.However,classic thermo-shaping usually requires lengthy

8、 heating cycles for ovens and heating plates.,New thermo-shaping technique,Fully automated processStandard thermo-forming machine(e.g.,Geiss T9)Cycle time up to 2 minutesSheets up to 60mm thick can be shapedHeating occurs at the top and bottom using IR Flash“spotsIntensity of IR heating elements can

9、 be individually controlledBoth heating areas move in and out separately to a holding position to allow molds to move into the required position,Page|12,Shaping principles,upper heater,lower heater,mold,RC sheet,blank holder,Page|13,Shaping with a double-sided mold,Shape highly complex partsVary thi

10、ckness in a single part using material compressionSandwich manufacturing with thermoplastic face sheets can be shaped in one stepNo cell crushing local compaction leads to higher mechanical properties since density is increasedDie-cutting in the mold eliminates additional milling steps,Page|14,ROHAC

11、ELL New Innovations,Page|15,Mass production with ROHACELL products New thermo-shaping technique Innovative“In Mold Foaming”,ROHACELL New Innovations,Page|16,Innovative“In-Mold Foaming”,Tight tolerances,integrated inserts,With In-Mold Foaming,inserts can be easily integrated into the part during the

12、core foaming process.,The newest product technology from Evonik is ROHACELL Triple F.A PMI chemistry-based particle foam that can be foamed in a mold to create geometrically complex parts with very tight tolerances.,ROHACELL New Innovations,Page|17,Mechanical behavior ofROHACELL Triple F,A strong,bu

13、t extremely lightweight core.,Depending on the part/process requirements,cores can be produced in a customized density range between 70 200kg/m or more.,When using carbon fibers,you do not want more weight in the core.,ROHACELL New Innovations,Page|18,Thermal behavior ofROHACELL Triple F,Use the ful

14、l temperature performance of the resin.,The Tg of ROHACELL Triple F(200C)is significantly higher than the Tg of all commonly used resins.,The temperature resistance of the part depends on the glass transition temperature(Tg)of the resin.To reach that Tg one has to cure at a temperature above the Tg

15、of the resin.,ROHACELL New Innovations,Page|19,Process benefits with ROHACELL Triple F,Speed up the curing process.,ROHACELL Triple F processing conditionsTemperature:up to 140C and Pressure:up to 6 MPa,High temperatures and injection pressure shorten the curing cycle time for RTM or wet pressing,So

16、urce:data sheet HexFlow RTM6 from Hexcel,ROHACELL New Innovations,Page|20,Process benefits withROHACELL Triple F,Improvement of process with stable material.,No outgassing due residual chemical reactions that can restrict adhesion of layers.The cores have a high fault tolerance due the particle stru

17、cture.Tight tolerances are possible.,Reduce manufacturing costs related to:timematerialsprocessing,ROHACELL New Innovations,Page|21,Process benefits with ROHACELL Triple F,ROHACELL Triple F cores are ready to use.No need for:,Evacuation due outgassing,Potting holes on the surface,Sanding,Inserts can

18、 be integrated into the part during the molding process.,Page|22,Conclusion,Lightweight design is required by the OEMThe lightest design principle is composite sandwichThe main hurdle for composites in automobiles is costTo reduce processing costs,new curing processes are available and will be developed further For all new curing methods ROHACELL could be used as sandwich coreNew mass production processes with ROHACELL products are available:New thermo-shaping technique Innovative“In Mold Foaming”,ROHACELL New Innovations,Page|23,