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Lenzing relies on wind power in the fiber and pulp production (c) Lenzing AG
At the ground-breaking ceremony, from left to right: Josef Reiter (Mayor of Engelhartstetten) Thomas Östros (Vice-President of the European Investment Bank) Helga Krismer-Huber (Green Party Lower Austria LAbg) Stephan Pernkopf (Deputy Governor of Lower Austria) Leonore Gewessler (Minister for Climate Protection) Gregor Erasim (owner of WLK energy) Gerda Holzinger-Burgstaller (Chairwoman of the Management Board of Erste Bank Österreich) Bianca Flesch (Environmental Management Messer Austria GmbH) Mario Wohanka (WLK Chief Financial Officer) Christian Skilich (CTO Lenzing AG)
10.11.2023

Lenzing relies on wind power in the fiber and pulp production

The Lenzing Group has concluded a supply contract with the Austrian electricity producer WLK energy for the purchase of around 13 megawatts of wind power. Lenzing is thus not only underlining its commitment to climate protection and the energy transition, but is also making a long-term investment in a price-stable and diversified electricity supply. The contract has a term of 15 years and provides for supply from the new wind farm in Engelhartstetten from the first quarter of 2025.

The construction of the wind farm is a joint project involving several partners, including the operator and electricity supplier WLK energy, based in Untersiebenbrunn (Lower Austria). The total output of the wind farm with a total of eleven wind turbines will be around 45 megawatts. The share of around 13 megawatts, which will be produced exclusively for the needs of the Lenzing site (Upper Austria), corresponds to the average electricity requirements of around 10,000 households per year in Austria. The ground-breaking ceremony to mark the start of construction took place on November 09, 2023 with representatives from politics and business.

The Lenzing Group has concluded a supply contract with the Austrian electricity producer WLK energy for the purchase of around 13 megawatts of wind power. Lenzing is thus not only underlining its commitment to climate protection and the energy transition, but is also making a long-term investment in a price-stable and diversified electricity supply. The contract has a term of 15 years and provides for supply from the new wind farm in Engelhartstetten from the first quarter of 2025.

The construction of the wind farm is a joint project involving several partners, including the operator and electricity supplier WLK energy, based in Untersiebenbrunn (Lower Austria). The total output of the wind farm with a total of eleven wind turbines will be around 45 megawatts. The share of around 13 megawatts, which will be produced exclusively for the needs of the Lenzing site (Upper Austria), corresponds to the average electricity requirements of around 10,000 households per year in Austria. The ground-breaking ceremony to mark the start of construction took place on November 09, 2023 with representatives from politics and business.

In 2019, Lenzing was the first fiber manufacturer to set itself the goal of reducing its CO2 emissions by 50 percent by 2030 and becoming carbon-neutral by 2050. This CO2 reduction target was recognized by the Science Based Targets Initiative. In 2022, Lenzing opened Upper Austria's largest open-space photovoltaic plant together with Verbund and also signed an electricity supply contract for photovoltaic energy with the green electricity producer Enery and Energie Steiermark.

Source:

Lenzing AG

Flachs-Koeper-Band (c) vombaur
Flachs-Koeper-Band
20.09.2023

Technical textiles made of natural fibres: Sustainable textiles for lightweight design

The combination of high strength and rigidity with sustainability and a neutral carbon footprint makes flax the ideal raw material for natural fibre-reinforced plastics. vombaur offers composite textiles made of this natural fibre for the automotive, wind power, construction or sports industries and many other sectors.

Flax fibres are rigid and tear-proof. They have natural bactericidal properties, are virtually antistatic, stain resistant and easy to spin. Humans have taken advantage of these properties to manufacture robust, stain-resistant and lint-free textiles. Between the late 19th and late 20th centuries, cotton largely replaced natural fibres. Because flax can be grown in Europe and consumes less energy and water than cotton production, the material's importance is currently growing again, for both clothing and composites. Regional textile value added chains in Europe – flax makes them possible.

The combination of high strength and rigidity with sustainability and a neutral carbon footprint makes flax the ideal raw material for natural fibre-reinforced plastics. vombaur offers composite textiles made of this natural fibre for the automotive, wind power, construction or sports industries and many other sectors.

Flax fibres are rigid and tear-proof. They have natural bactericidal properties, are virtually antistatic, stain resistant and easy to spin. Humans have taken advantage of these properties to manufacture robust, stain-resistant and lint-free textiles. Between the late 19th and late 20th centuries, cotton largely replaced natural fibres. Because flax can be grown in Europe and consumes less energy and water than cotton production, the material's importance is currently growing again, for both clothing and composites. Regional textile value added chains in Europe – flax makes them possible.

Ideal mechanical properties
vombaur makes the mechanical properties of flax usable for lightweight design. Because flax fibres are particularly rigid and tear-resistant, they ensure great stability in natural fibre-reinforced plastics (NFRPs). And thanks to their low density of 1.50 g/cm3, the fibres weigh virtually nothing. On top of this, fibre-reinforced plastics are less prone to splintering than glass fibre-reinforced plastics.

Excellent carbon footprint
The cultivation of flax binds CO2 and the production of natural fibre-reinforced plastics (NFRPs) generates approximately one third less CO2 emissions compared with conventional fibre-reinforced plastics. Energy consumption is substantially lower. This saves resources. The use of flax fibre tapes by vombaur in lightweight design applications also improves the product's carbon footprint and contributes to a secure, regional supply chain.

Recycling without impacting on quality
Flax offers another sustainability benefit: more recycling cycles than glass- or carbon fibre-reinforced plastics – without impacting on quality. Thermoplastic fibre-matrix prepregs are melted and reused in the recycling process. The natural fibres can be used in other products such as natural fibre-reinforced injection moulded parts.

Sustainable product developments for many industries
"Orthoses for high-performance sports, high-tech skis, wind turbines, components for the automotive industry or aerospace, but also modern window profiles – the application scope for our lightweight design flax tapes is amazingly diverse", as Carl Mrusek, Chief Sales Officer at vombaur explains. "After all, wherever flax tapes are used, three key properties come together: light weight, strength and sustainability".

More information:
CO2
Source:

vombaur

Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz Hanns-Voith-Stiftung, Oliver Voge
Professor Dr Thomas Gries with the award winner Flávio André Marter Diniz
11.07.2023

Future cost reduction through ultra-thin PE carbon fibres

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

  • ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

The use of carbon fibres in highly stressed lightweight construction solutions, such as today's growth applications of wind turbines or pressure tanks, has become indispensable due to their excellent mechanical properties and low density. High manufacturing costs of conventional PAN precursor-based carbon fibres make the material very cost-intensive. In addition, it is not sufficiently available. New manufacturing approaches that develop alternative raw materials and manufacturing processes can be a key and growth engine for further industrial composites applications.

The aim of the work was to develop a new and cost-effective manufacturing process for high-quality ultra-thin carbon fibres using a polyethylene precursor. For this purpose, the sulphonisation process, which is time-consuming today, was to be significantly shortened. As a result, Mr. Marter Diniz produced novel ultra-thin polyethylenebased carbon fibres with a filament diameter < 3 μm with an excellent surface quality of the fibres without detectable structural defects. The fibre diameter is 2-3 times smaller than that of conventional PANbased CF. This provides the basis for mechanically high-quality material properties. At the same time, Mr. Marter Diniz was able to reduce the sulphonisation time by 25 percent. The developed material and technology set important milestones on the way to cheaper carbon fibres. With PE-based precursors, the price of CF can be reduced by 50 percent compared to conventional PAN-based CF.  

A total of five other young scientists were awarded in six categories (Drive Technology, Innovation & Technology/Artificial Intelligence, New Materials, Paper, Hydropower and Economic Sciences. This year, for the 10th time, the Hanns Voith Foundation awarded the Hanns Voith Prize to outstanding young scientists.

Source:

ITA Institut für Textiltechnik of RWTH Aachen University

05.05.2023

SGL Carbon: Business Development in Q1 2023

  • Sales increase by 4.7% to €283.7 million in Q1 2023
  • Adjusted EBITDA improves by 9.0% to €40.1 million
  • Growth based in particular on strong demand from the semiconductor industry

SGL Carbon generated Group sales of €283.7 million in Q1 2023 (Q1 2022: €270.9 million). This corresponds to an increase of €12.8 million or 4.7% compared to the same period of the previous year. Increased demand for specialty graphite components for the semiconductor industry from the Graphite Solutions business unit contributed in particular to the pleasing increase in sales. But also the Process Technology and Composite Solutions business units continued their positive business development.

Accordingly, adjusted EBITDA (EBITDApre) improved by 9.0% to €40.1 million in the reporting period (Q1 2022: €36.8 million).

  • Sales increase by 4.7% to €283.7 million in Q1 2023
  • Adjusted EBITDA improves by 9.0% to €40.1 million
  • Growth based in particular on strong demand from the semiconductor industry

SGL Carbon generated Group sales of €283.7 million in Q1 2023 (Q1 2022: €270.9 million). This corresponds to an increase of €12.8 million or 4.7% compared to the same period of the previous year. Increased demand for specialty graphite components for the semiconductor industry from the Graphite Solutions business unit contributed in particular to the pleasing increase in sales. But also the Process Technology and Composite Solutions business units continued their positive business development.

Accordingly, adjusted EBITDA (EBITDApre) improved by 9.0% to €40.1 million in the reporting period (Q1 2022: €36.8 million).

Sales development
In the first three months of fiscal year 2023, the business unit Graphite Solutions was the main driver of SGL Carbon's growth with an increase in sales of €21.3 million or 17.8%. This is due in particular to the reallocation of production capacities from the solar industry market segment to the semiconductor industry. The Process Technology (+€6.6 million) and Composite Solutions (+€4.0 million) business units also contributed to the increase in sales.

The Carbon Fibers (CF) business unit recorded a decline in sales of €24.0 million in the reporting period. The decline is mainly due to the scheduled expiry of the attractive supply contract for the BMW i3 in the middle of last year. Freed-up production capacities were compensated by orders from the wind industry in the 2nd half of 2022. But the necessary construction of wind turbines in Europe is currently stalling. Low building permits and high manufacturing costs are temporarily hampering the construction and expansion of wind parks and therefore the necessary increase in renewable energy.

Earnings development
In line with the sales development combined with higher capacity utilization and positive product mix effects, adjusted EBITDA (EBITDApre) improved from €36.8 million to €40.1 million in Q1 2023, representing a quarter-on-quarter increase of 9.0%.

Taking into account depreciation and amortization of €14.3 million (Q1 2022: €14.1 million) as well as one-off effects and non-recurring items of minus €0.1 million, EBIT in the reporting period amounted to €25.7 million (Q1 2022: €31.2 million). It should be noted that Q1 of the previous year was positively impacted by one-off effects and and non-recurring items amounting to €8.5 million. Accordingly, net profit for the period of €15.3 million was lower than in the same quarter of the previous year (€21.5 million).

Debt, equity and capitel expenditure
Net financial debt increased slightly to €174.2 million as of March 31, 2023 (Dec. 31, 2022: €170.8 million). The leverage ratio remains unchanged at 1.0. Due to the positive consolidated net income, the equity ratio increased again slightly compared to the end of fiscal 2022 to 39.5% (Dec. 31, 2022: 38.5%).

Looking at the capital expenditure in Q1 2023, it amounted to €19.0 million, which is higher than the average values of the previous quarters. "At the beginning of 2023, we had already announced the expansion of our investment activities to expand production capacities in the Graphite Solutions business unit. In previous years, our capital expenditure was in line with depreciation and amortization. In addition to these approximately €60 million, we will invest further €20 to €30 million in 2023, which will be financed by advance payments in the context of long-term supply contracts from our customers in the semiconductor industry. Our semiconductor customers secure future production capacities for graphite components, which are needed for their own growth. In return, SGL Carbon's long-term supply contracts will enable future profitable growth," said Dr. Torsten Derr, CEO of SGL Carbon.

Outlook
In line with the business performance in the first three months of 2023, the company confirms the sales and earnings guidance issued on March 23, 2023.

For the financial year 2023, Group sales are expected to be at the prior-year level and  EBITDApre between €160 - 180 million. Taking into account depreciation and amortization, EBITpre is forecast to be between €100 - 120 million. Furthermore, free cash flow at the end of fiscal 2023 is expected to be at the prior-year level and return on capital employed (ROCE) between 10% and 12%.

Source:

SGL CARBON SE

Photo: Monforts
The new seven chamber Montex TwinAir stenter range with Montex®Coat coating at the plant.
26.10.2022

Dolinschek: Compression stockings in a variety of colours

The identification of profitable new niche markets has been central to the success and continuous expansion of Germany’s Dolinschek, a leading knitting, dyeing and finishing specialist, located in Burladingen in Baden-Württemberg.

“There is so much more to textiles than just clothing,” says Theo Dolinschek, who runs the company with his brother Erwin. “We handle many different technical materials such as automotive components, geotextiles and wallcoverings, but also those for more unusual applications such as inlays for extractor hoods, cut protection fabrics and even wool felts which are employed as insulation on wind turbines.

“We have also recently started to produce compression stockings in a variety of colours, because not everyone wants them black, beige or skin coloured. The most important product areas for us now are in sportswear, corsetry and lingerie, as well as orthopedic and medical products, workwear and protective clothing, but in addition, many other technical applications.”

The identification of profitable new niche markets has been central to the success and continuous expansion of Germany’s Dolinschek, a leading knitting, dyeing and finishing specialist, located in Burladingen in Baden-Württemberg.

“There is so much more to textiles than just clothing,” says Theo Dolinschek, who runs the company with his brother Erwin. “We handle many different technical materials such as automotive components, geotextiles and wallcoverings, but also those for more unusual applications such as inlays for extractor hoods, cut protection fabrics and even wool felts which are employed as insulation on wind turbines.

“We have also recently started to produce compression stockings in a variety of colours, because not everyone wants them black, beige or skin coloured. The most important product areas for us now are in sportswear, corsetry and lingerie, as well as orthopedic and medical products, workwear and protective clothing, but in addition, many other technical applications.”

The Dolinschek brothers moved their business to the historic site of the former Ambrosius Heim textile company in Burladingen in 2001 in order to expand. At the time, the company – founded by their father in 1980 as a textile wholesaler before moving into dyeing – employed just 13 people. Within a year, the company had bought additional space at the site.

Now, with Theo in charge of technology and sales, and Erwin responsible for production, the company employs almost 100 people and operates on an integrated site of 35,000 square metres.

In 2005, a laminating department was established by the company and since 2012 investment in knitting machines has been ongoing.

“The further we went into vertical integration, the more of our own products we were able to position on the market and so we were also able to make ourselves more independent,” says Theo. “We have continued to develop and today we can produce high-quality fabrics for many fields, with 42 knitting machines, 36 dyeing machines, three stenter frames and many other production and processing machines.”

Dolinschek has also developed its own proprietary TMG dyeing machines which have subsequently been successfully sold to many other companies all over the world. There are currently 11 of these machines  in operation at the Burladingen site and around 45 installed at other companies.

For finishing technology, however, the company relies on Monforts, and has installed a new seven chamber Montex TwinAir stenter range with a Montex®Coat coating unit in knife execution, enabling the coating of dimensionally stable knitted fabrics with polyurethane or acrylate. Another unique feature is the Teflon-coated (non-stick) transportation belt through the system.

The Montex line is also equipped with integrated heat recovery and exhaust gas purification to ensure the most resource-efficient processing available on the market. The exhaust air goes from the Monforts heat recovery system into an existing air/water heat recovery system and then into an electrostatic precipitator.

Highly-intuitive Monforts Qualitex visualisation software allows all machine functions and process parameters to be assessed and controlled easily.

 

More information:
Dolinschek Monforts
Source:

AWOL Media

Foto: Freudenberg Performance Materials
11.08.2022

Freudenberg Friction Inserts at WindEnergy Hamburg 2022

Freudenberg Performance Materials is introducing Freudenberg Friction Inserts to trade visitors at WindEnergy, the leading trade fair for the international wind energy industry. Freudenberg Friction Inserts is a unique technology aimed at increasing the power density of wind turbines.

The Freudenberg Friction Inserts (FFI) technology is based on a special very thin nonwoven carrier material coated on one side with hard particles. The FFI are customized to fit each application, in terms of both the geometry and the construction parameters of the connection. As they do not create a gap they can be applied exactly where they are needed.

When placed in the joint, these hard particles penetrate into the surfaces of the two joining parts creating a micro interlock, thus reliably increasing the friction coefficient and achieving higher torque transmission in connections. This results in higher performance and a significant improvement in the efficiency of wind turbines. In addition, it enables the downsizing of components without compromising performance, reducing weight and material.

Freudenberg Performance Materials is introducing Freudenberg Friction Inserts to trade visitors at WindEnergy, the leading trade fair for the international wind energy industry. Freudenberg Friction Inserts is a unique technology aimed at increasing the power density of wind turbines.

The Freudenberg Friction Inserts (FFI) technology is based on a special very thin nonwoven carrier material coated on one side with hard particles. The FFI are customized to fit each application, in terms of both the geometry and the construction parameters of the connection. As they do not create a gap they can be applied exactly where they are needed.

When placed in the joint, these hard particles penetrate into the surfaces of the two joining parts creating a micro interlock, thus reliably increasing the friction coefficient and achieving higher torque transmission in connections. This results in higher performance and a significant improvement in the efficiency of wind turbines. In addition, it enables the downsizing of components without compromising performance, reducing weight and material.

FFI help to improve the reliability of connections and thus of the entire wind turbine. Furthermore, they eliminate slipping and prevent fretting of connections.

Other examples of applications for FFI are highly loaded flange connections between the rotor shaft and gearbox, connections between the main bearing and the machine carrier housing, the gearbox to generator, or at the pitch gear or ring gear. They increase the friction co-efficient between two components.

Source:

Freudenberg Performance Materials

(c) AVK - Industrievereinigung Verstärkte Kunststoffe e. V.
24.11.2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – presents its Innovation Awards 2021

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

Category “Research and Science”
First place in the “Research and Science” category was awarded to the German Aerospace Center (DLR) for its Bondline Control Technology (BCT). This innovative process is used for quality control and assurance of bonded joints. The core element is a porous fabric which is applied to a joining surface using an epoxy adhesive or matrix resin. Peeling away the fabric creates a chemically reactive and undercut surface and can also be used as a test to check adhesion to the substrate. BCT has potential in a variety of possible applications. For example, peel ply can be replaced by BCT fabric to produce composite components with an optimised joining surface. The cost-effective BCT peel test is suitable for coupon testing and process control. In addition, the combined adhesion test and surface pre-treatment can be used for quality assurance of bonded repairs on fibre composite structures.

Second place was taken by the Institute of Textile Technology (ITA) at RWTH Aachen University and its partners AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR with “StoneBlade – Lightweight construction with granite for the wind industry”. This innovation enables manufacturers to reduce the amount of non-recyclable materials used in rotor blade construction. At the same time, it reduces the weight of these components and improves the mechanical properties relating to the stability of wind turbines. The innovative approach replaces glass-fibre reinforced plastic in the blade components with hard rock – a natural, cost-effective and recyclable lightweight material. The slabs of rock are cut and ground to a thickness of just a few millimetres and embedded in a fibre composite laminate with carbon fibre, which stabilises them for alternating load cases. The pre-stressed material is pressure-stable in the composite and can absorb tensile forces in the event of continuously alternating loads without any loss of stiffness.

Third place went to the Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK) with its partner Mercedes Benz AG for the interdisciplinary development of a highly integrated inductive charging module for electric vehicles. The ultra-thin charging module was designed to make optimum use of space in the vehicle underbody without reducing ground clearance. An interdisciplinary approach was adopted for the development process. This involved the electrical, mechanical and process characterisation of high-frequency Litz wires, ferromagnetic foil and metal wire cloth as well as the creation of a simulation model. The result is a demonstrator for a charging system with a structural height of 15 mm and a total weight of 8 kg. It achieves a transmission efficiency of up to 92 percent at 7.2 kW nominal power and active air cooling. The hardware demonstrator was fabricated in a 3-step process using RTM and VARI techniques.

Overview of all the winners in the three categories:
Category “Innovative Products/Applications”
1st Place: “Traffic signs from Nabasco (N-BMC)” – Nabasco Products BV and Lorenz Kunststofftechnik GmbH, partners: Pol Heteren BV and NPSP BV
2nd Place: “Novel, ultratough vinyl ester resin for the construction of large marine vessels” Evonik Operations GmbH
3rd Place: “Air intake housing with a multi-material design for gas turbines” – MAN Energy Solutions SE, Leichtbau-Zentrum Sachsen GmbH and Leichtbau-Systemtechnologien KORROPOL GmbH.
Category “Innovative Processes”
1st Place: “In-mould wrapping” off-tool, film-coated, fibre composite components for exterior applications – BMW Group, Partner: Renolit SE
2nd Place: “Adaptive automated repair of composite structural components in the aviation sector” – Lufthansa Technik AG, Partner: iSAM AG
3rd Place: “Automated surface pre-treatment using VUV excimer lamps” – CTC GmbH
Category “Research and Science”
1st Place: “Bondline Control Technology (BCT)” – German Aerospace Center (DLR)
2nd Place: “StoneBlade – Lightweight construction with granite for the wind industry” – Institute of Textile Technology at RWTH Aachen University, Partners: AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR
3rd Place: “Interdisciplinary development of a highly integrated inductive charging module for electric vehicles” – Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK), Partner: Mercedes Benz AG

Submissions for the next Innovation Award can be made from the end of January 2022.

Source:

AVK - Industrievereinigung Verstärkte Kunststoffe e. V.

15.02.2021

Hexcel’s HexPly® XF Surface Technology for Blade Surface Finishing Process

Hexcel announces its latest HexPly® XF surface technology that reduces shell manufacturing time within the wind blade surface finishing process. HexPly XF increases overall blade manufacturing efficiency by reducing time in the mold by up to two hours and by banishing surface defects that require rework before painting.

Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology introduces a new material format as the surface finishing layer, eliminating the need for a traditional in-mold gel coating process. HexPly® XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Hexcel announces its latest HexPly® XF surface technology that reduces shell manufacturing time within the wind blade surface finishing process. HexPly XF increases overall blade manufacturing efficiency by reducing time in the mold by up to two hours and by banishing surface defects that require rework before painting.

Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology introduces a new material format as the surface finishing layer, eliminating the need for a traditional in-mold gel coating process. HexPly® XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Easy to handle and supplied in a ready to use roll form, HexPly XF can be quickly applied by hand or with semi-automated layup equipment. It features one self-adhesive, surface finishing side - indicated by a removable protective foil. This side of the prepreg is placed against a release agent treated mold surface. Once the material has been positioned, the lay-up of the blade shell structure can start immediately, and the laminate can be infused. After curing, the blade is de-molded with the manufacturer benefitting from a pinhole-free surface that needs minimal preparation before painting.

HexPly XF material is less than half the weight of a typical gel coat per square meter, reducing the overall weight of the blade. Additionally, the consistent areal weight and thickness of the prepreg film provide a completely uniform surface coating, ensuring blade weight distribution and balance are maintained, which is critical as rotor diameters continue to increase. With no need to handle or mix liquid chemicals as in the gel coat process, HexPly® XF also improves the health and safety working conditions on the shop floor.

The material has a shelf life of six weeks at ambient temperature, which also minimizes cold storage requirements and helps to reduce scrap.

Source:

100% Marketing

09.02.2021

Sicomin: Collaboration with GREENBOATS® for natural fibre composite

Sicomin announces its latest collaboration with GREENBOATS® as they deliver the first ever natural fibre composite (NFC) nacelle for an offshore wind turbine.  

With more than 2.5 million tons of composite materials in use in the wind industry globally, and the first generation of wind turbines now approaching end of life, there is still a lack of well-established recycling options. GREENBOATS’ mission is to demonstrate how large-scale NFC structures in wind energy can lower energy consumption in manufacturing and significantly improve the sustainability of the composite materials used in the turbine.

In 2020, GREENBOATS was commissioned by a leading wind energy technology developer to design and manufacture a sustainable NFC nacelle. The resulting 7.3m long structure has a surface area of approximately 100m2 and was engineered by GREENBOATS to satisfy all DNV-GL load cases required for an offshore turbine nacelle, including 200km/h max wind loads and 2KN loads on the guard rails.

Sicomin announces its latest collaboration with GREENBOATS® as they deliver the first ever natural fibre composite (NFC) nacelle for an offshore wind turbine.  

With more than 2.5 million tons of composite materials in use in the wind industry globally, and the first generation of wind turbines now approaching end of life, there is still a lack of well-established recycling options. GREENBOATS’ mission is to demonstrate how large-scale NFC structures in wind energy can lower energy consumption in manufacturing and significantly improve the sustainability of the composite materials used in the turbine.

In 2020, GREENBOATS was commissioned by a leading wind energy technology developer to design and manufacture a sustainable NFC nacelle. The resulting 7.3m long structure has a surface area of approximately 100m2 and was engineered by GREENBOATS to satisfy all DNV-GL load cases required for an offshore turbine nacelle, including 200km/h max wind loads and 2KN loads on the guard rails.

Sicomin’s market leading GreenPoxy® range met these challenging engineering requirements, with the company’s recently expanded manufacturing capability also matching the potential supply volumes required by wind turbine manufacturers.  

Sicomin’s DNV-GL type approved bio-based epoxy was used to infuse BComp flax fibre reinforcements and balsa cores, with Sicomins’ intumescent weatherproof gelcoat applied on the outer surface. Cured panels were cut to shape, formed over a male plug and bonded together, before flax reinforcement plies, hand laminated with GreenPoxy resins and vacuum bagged, were added along all the panel joints lines.  Finally, Sicomin’s highly UV resistant clear coating products were used to protect and enhance the finish of the flax fibre feature stripe details.

Source:

100% Marketing