1. introduction of toray and zoltek 2. automotive ... · sheet moulding compound . confidential 20...

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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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Global Business Network

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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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HP RTM


High Material Flexibility High Capex

High performance High Scrap rate due to cu?ng out

Class A surface Preforming



Source: Hexion

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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


High Material Flexibility High Capex

High performance

Reduced Scrap



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


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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


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


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


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


Moulding Compound

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2. Automotive Applications Thermoplastic Composites


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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Nylon

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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

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The Industry Standard For Carbon Fiber In Automotive

1. introduction of toray and zoltek 2. automotive ... · sheet moulding compound . confidential 20...

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