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Production Process of
Non Crimp Fabrics [NCF]
for aviation applications
Composites without borders 2014-10-15 Moskau Rainer Seuß
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Company profile
Multiaxial structures
Spreading technology
MAX 5 technology
Application
Content
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KARL MAYER Group
KARL MAYER Schweiz, Uzwil
Verkauf, Service, Produktion
KARL MAYER, Obertshausen KARL MAYER MALIMO, Chemnitz
LIBA Textilmaschinenfabrik, Naila
KARL MAYER ROTAL Italien, Mezzolombardo
NIPPON MAYER
Japan, Fukui
KARL MAYER
China, Changzhou
Service
KARL MAYER Indien, Mumbai
KARL MAYER Nord Amerika, USA, Greensboro
KARL MAYER GB, Shepshed
KARL MAYER Hongkong
Verkauf, Service
Produktion
(ab 2014 in Indien)
Ca. 2300 employees
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Company Profile
NAILA
1945 Foundation of LIBA Maschinenfabrik
1948 production of first tricot machine
1983 start development multixial technology
2014 Acquisition by Fa. KARL MAYER
2014 Foundation of KARL MAYER subsidiary
KARL MAYER LIBA Textilmaschinenfabrik GmbH
Located in Naila, Germany
330 employees in Naila
50 employees in R&D
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Milestones
1983
Start
multiaxial
technology
development
1998
Product
launch MAX 3
2002
Product
launch MAX 5
2007
Product launch
Offline spreading
machine UD 500
2010
Product launch
MAX 5
automotive
2009
Product
launch MAX 4
2004
Start
spread
technology
development
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Competence
More than 30 years experience with multiaxial technology
More than 25 years experience of processing
carbon, glass and aramid fabric
More than 10 years experience in spreading
of high performance fibers e.g. carbon fibers, class fibers
More than 15 years experience as a development partner
in automotive, aerospace and wind energy industries
Over 200 multiaxial machines installed worldwide
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Competence
Produced on Karl Mayer LIBA machines
Preforming/
Tayloring Structural part
Textile
reinforcement Carbon fiber
Woven fabric
NCF
Spread tapes
Braiding
Etc.
Fiber reinforced composites : process chain
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Multiaxial fabric consists of one or more layers of differently aligned
held in place by a stitching yarn
Multiaxial fabric
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Multiaxial fabric
Multiaxial fabric Yarns remain straight, no crimp
Direct linear utilization of fiber strength
Different angles / more then two
angle directions in one fabric possible
Combination with additional material
due to the in-line process
Woven fabric Yarns bend over each other
(= web crimp)
Indirect utilization of fiber strength
Only 0°/90° directions possible
Why multiaxial fabrics ???
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Production of multiaxial structures
Endless weft insertion [MAX 4] – processing of rovings
Finite weft insertion [MAX 5] – processing of tapes
One weft insertion system for each angle position
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Production of multiaxial structures
Process flow
Production of multiaxial structures
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Production of multiaxial structures
Weft insertion
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Production of multiaxial structures
Tape quality inspection system
Inspection system for monitoring the tape structure regarding tape width an detecting defects in
the tape like gaps.
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Production of multiaxial structures
Insertion additional material
Weft insertion for thin yarns
Glass yarn 34 tex and 68 tex
Bottom ply for wide 0° plies
Insertion of thermoset yarn / hotmelt yarn
Let off system
Non woven structures
Core material
Grid structures
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Production of multiaxial structures
Walking needle system
Minimum load and tension = reduced wear on the needle system
Reduced stitch holes = improved fabric quality
Reduced friction = high production speed
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Production of multiaxial structures
Vario stitch
tailored patterning tailored stitchlength
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Production of multiaxial structures
Vario stitch
variable
vari
able
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Production of multiaxial structures
Coating and batching
Powder scattering system with infrared heating zone
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Production of multiaxial structures
Results – new opportunities
Multiaxial fabric with core material
Vario stitch
Tailored Vario stitch
Multiaxial fabric with thermoplastic ply
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Production of multiaxial structures
Results – new opportunities
Quasi organic tension curves
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Production of multiaxial structures
Summarize main topics
Modular machine concept
Available working width 50“ / 101“ / 130“
Processing of finite Tape structures
Weft insertion for pre spread tape structures 14“ wide
Weft insertion for online spread tape structures 12“ wide
Processing angle direction up to 20°, standard execution +/- 45° and 90°
For each ply one individual weft insetion system necessary
Feeding of 0° ply, arranged between weft insertion station or close to the stitching area
Clamping system to keep the tape structures in the right alignment
Production up to 180 m/h by using 14“ wide tapes
Variable patterning in production direction and also transversal to that
Connecting the laid plies by warp knitting technology
Drapility is adjustable by using the vario stitch technology
Apply powder to the multiaxial fabric for preforming pupose
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Production of spread tape structures
Why spreading carbon fiber tows ???
spreading
spread carbon fiber tow not spread (regular) carbon fiber tow
Carbon fiber tows are available in different sizes
(size unit: 1K = thousand filaments in tow‘s cross-section)
Low K tows (1K to 6K): - better impregnation
- expensive
High K tows (12K to 50K): - worse impregnation
- low priced
Spreading = Manufacturing of low areal weight unidirectional tapes from low priced carbon tows (>=12K)
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Production of spread tape structures
Offline spreading machine
Online spreading system
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Production of spread tape structures
Process flow
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Production of spread tape structures
Offline spreading machine
Tangential draw off Spreading zone
Omega roller system Batching spread tape
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Production of spread tape structures
Online spreading system
Direct feeding of spread tapes
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Production of spread tape structures
Online spreading system
-20,00
-10,00
0,00
10,00
20,00
30,00
40,00
50,00
laying cycle
v [m
/min
]
• Compensation of non-linear weft insertion speed by controlled creel motion
Spreading speed
Speed of online creel
Speed of gripper
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Production of spread tape structures
Results
Carbon fiber spread tape
Carbon fiber spread tape with powder
Carbon fiber spread tape with grid
Glass fiber spread tape with grid
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Production of spread tape structures
Summarize main topics
Modular machine concept
Spreading of carbon fibers , glass fibers, aramid fibers
Production of semifinished tape structures or also for enduser applications
Different creel systems avaiable, twist free unwinding
Individual spreading zones for 12K / 24K and 50K Carbon fibers
Tape width 800mm or 2x 355mm (14“)
Max. production speed 25 min-1
Sectional beam for batching up to 40“
Area weights from 75 gsm up to 400 gsm, depends of the fiber Spec.
Adding functional materials like powder or grid structures as top and/or bottom plies
Constant spreading speed for offline and online system
Spreading princip by vibration, yarn deflection and heat
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Applications for the industry
Wind power
Lightweight construction
Transportation
Aerospace
Sports
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Nachdruck, auch auszugsweise, sowie fotomechanische Reproduktion nur mit ausdrücklicher Genehmigung der Firma
KARL MAYER LIBA Textilmaschinenfabrik GmbH, 95119 Naila · Oberklingensporn 1 · Deutschland
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Thank you for your attention !