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Structural Composites Light Weighting Formulation Development for Carbon Fiber SMC and Prepreg
Opportunities in Automotive Components
Key SMC, BMC, and Prepreg ProjectsJim Bono- R&D US, Durham, High Temperature
SPE 2018 Thermoset Topical Conference - TOPCON
February 2018
• Market Outlook
• Applications and Processes for Advanced Composites
• Comparison of Processes
• CF Prepreg Materials
• CF Wet Press Molding
• HP-RTM CF
• CF/FG SMC Development
• Conclusions
Outline
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Growth of Light Weighting Materials in Automotive
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• Today- MaterialBreakdown- wt fraction• 2015vs.2030Growthoflightweightingmaterials
Materials for Light Weighting
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BMW Carbon Fiber Composite Applications
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Tensile Performance of Carbon Fiber Laminates
7Tensile Modulus (G Pa)
Tens
ile S
treng
th (M
Pa)
20050 6055 65 70
400
1,000
600
800
UDPrepreg
FabricPrepreg
HPRTM
WetPress
CFSMC12K
Part Weight Increases
Composite Fabrication Process SummaryHP-RTM Wet Process Prepreg SMC
Part Weight Lightest Heaviest
Part Cost Lowest
Lowest Costper Kg Saved Roof Rails Center Tunnel /
Rocker Panels B-Pillar Rear Package Shelf
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Automotive Applications Polylite® HS Prepreg Applications
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• Joint development with Reichhold under a collaboration agreement
• Creation of a novel Polylite® HS chemistry platform
• Step-change for composites chemistry landscape
&
Product Development Objectives
• Very short cycle times• Enable robotic handling of materials
for part manufacture• Eliminate the need for freezers
• Materials suited for structural parts
SolvaLiteTM 730:Next generation prepreg
Fast cureLow TackStorage StableGood Mechanicals
Lower Total Cost of Ownership
Product Overview and Value Proposition
Fast-curing: 180 seconds at 150°C60 seconds at 170°C
Key Properties Benefits
Ideal for high volume applications - 150K complex structural parts
Low tack Automation
Storage stable at room temperature for 6 months
Potential for improved durability
Tg of 130°C (DMA E’ onset) Components are hot demoldable
Lower enthalpy Manufacture of thick parts without risk of exotherm
Exceptional toughness
No freezer No defrosting timeNo temperature controlled transport
Enhanced mold release Processability/takt time
One Minute Cure Capability
Fast Cure confirmed by Dielectric Analysis (DEA)
DEA sensor embedded into the compression mold tool to make direct measurements during the cure.
Robust thermal and mechanical properties after fast processing
Characteristic
Polylite HS35500-00 50K Tow
Carbon FIber
Polylite HS35051-00 24K Tow
Carbon Fiber
Epoxy Control50K Tow
Carbon FiberFlex Strength- 0°(MPa) 1,827 1,531 1,695Flex Modulus- 0°(GPa) 122.0 114 131.4Flex Strength- 90°(MPa) 69 85Flex Modulus- 90°(GPa) 9,1 8.8Tensile Strength- 0°(MPa) 2,149 1,979 1,962Tensile Modulus- 0°(GPa) 129.0 133 156.0Tensile Strength- 90°(MPa) 40.8 51.9Tensile Modulus- 90°(GPa) 11.0 9.8Interlaminar Short Beam Strength(MPa) 107.1 90.5 94.9
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Prepreg Unidirectional Polylite HS Hot Melt Vinyl Hybrid
Vinyl Hybrid andEpoxy Have SimilarMechanical PerformanceOn Carbon Fiber
Chevy Spark Composite Electrical Battery Tray
Automotive Applications of Vinyl Hybrids
Automotive Applications CF Wet Press/ HP-RTM Applications
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Automotive Cycle Productivity
Assumptions:7 hr shift (1 hr breaks), 3 shifts per day, 5 day work week, 50 weeks per year85% Overall Equipment Efficiency
Can be obtained simultaneously
Target–SnapCureDefinition
Wet Press Mechanical Properties (Carbon Fiber)
Polylite HS EpoxyFiber Volume Fraction
47 47
Tensile Modulus, GPa
64.1 55.0
Tensile Strength, MPa
642.7 690.0
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Automotive Applications of Vinyl HybridsChevrolet Corvette Composite FloorboardSandwich Construction:• Glass Mat/Plastic Foam Core• Polylite HS – Liquid Vinyl Hybrid Resin• Process: Wet Process with heated steel tool
Polylite HS HP-RTM Mechanical Properties (Carbon Fiber)
PolyliteHS Dion9100 Dion31638:31100 Epoxy
ResinChemistry VinylHybrid VinylesterHybrid
Vinylester:Urethane
Epoxy
FiberVolumeFraction 50 50 50 50
Interlaminar ShearStrength,MPa
26.4EpoxySizedCF
55.2VE SizedCF
40.5EpoxySizedCF
50.30VE SizedCF
63.60EpoxySizedCF
60.08VE SizedCF
47.90EpoxySizedCF
47.70VE SizedCF
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Target 90 seconds for cure time meet at multiple initiator loadings and mold temperatures
Polylite HS 35501-00 Vinyl Hybrid Resin –Dielectric Cure Analysis- Initiator Type vs. Mold Temperature
Automotive Applications Carbon Fiber SMC
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CF SMC Based on Polylite® HS Resin Mechanical Properties (12K Tow)
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Property Test Method Units Polylite HSStyrenated
VEFiber %wt ASTM D3171 % 50 50Specific Gravity ASTM D792 g/cm3 1.48 1.42Tensile Strength ASTM D638 MPa 193 220Tensile Modulus ASTM D638 GPa 57 65Flex Strength ASTM D638 MPa 448 586Flex Modulus ASTM D638 GPa 31 52
MoldedTensileandFlexBars
CF SMC Based on Polylite® HS and Dion VER Resin Mechanical Properties (3K Tow)
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Property Test Method Units X4885-70Developmental
ResinStyrenated
Dion VE
Fiber %wt ASTM D3171 % 50 50 50Specific Gravity ASTM D792 g/cm3 1.47 1.42 1.47Tensile Strength ASTM D638 MPa 253.6 317.3 327.5Tensile Modulus ASTM D638 GPa 41.2 42.1 37.2Flex Strength ASTM D638 MPa 420.1 538.8 551.6Flex Modulus ASTM D638 GPa 33.0 36.8 33.8
CutTensileandFlexBars
Thermomechanical Property Retention
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Temperature (°C)
Prop
erty
Ret
entio
n (%
)
Co- molding CF Prepreg: CF SMC
CORE SHELL IMPACT MODIFIER
CSR
• Dissipates Energy –Reduces damaged area
• Crack Terminator – Interlaminar bond & peel strength improvement
• Relieves Inherent Stress during Curing –Dimensional stability & micro crack resistant
Toughening Additives- CSRVE
Toughening Additives- CSRVE
Multi Drop Ball Impact on 3 Plies of E-Glass Mat from 2, 3, 4 and 9 Feet
PolyesterURHybrid CSRVE
VE CTBNVE
100EastCottageAvenue|Carpentersville,IL60110|www.pccrusa.com 31
Typical Tensile Properties of the Various Base Resins
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14
Stress (psi)
Strain (in/in)
Epoxy2CSRVE2
DCPD
StandardVE
Epoxy1CSRVE1
Conclusions• Light weighting is a market need for several segments- including
automotive. CF Advanced composites will play a critical part in material selection decisions by various platforms.
• Polylite HS Vinyl Hybrid styrene free resins meet the cycle time requirements of high volume serial automotive production with cure times as fast as one minute.
• Polylite HS Vinyl Hybrid resins can be used in Prepreg, Wet Compression, HP-RTM and CF SMC applications.
• Polylite HS Vinyl Hybrid resins have similar thermomechanical performance as compared to epoxy resin.
• CSR-VE offers opportunities to improve fracture toughness and increase elongation with minimal effect on overall strength.
• Commercial formulated composite companies have developed and continued to develop commercial products based on the novel Polylite HS resin chemistry.
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Questions?Jim Bono- Polynt US Composites [email protected]
Acknowledgements:Solvay CompositesGerald Perrin, Serial Automotive Program [email protected]
IDI Composites InternationalKevin Cahill, [email protected]
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