From the Sector

At the joint stand of the Aachen Centre for Integrative Lightweight Construction (AZL) in Hall 5A, booth D17, the Institut für Textiltechnik of RWTH Aachen University (ITA) will demonstrate its expertise in the field of glass fibres, preforms and textile concrete 12-14 March 2019 in Paris.
The exhibits come from various fields of application and address the automotive, aerospace and mechanical engineering sectors.

1. Innovative glass fibre research at ITA
   The newly constructed induction heated glass fibre production line enables increased flexibility in research. For the first time, glass fibres will be produced live at the ITA booth at JEC World. One of the innovations of the system is the inductively heated bushing. It features a flexible design and consists of a platinum/rhodium alloy (Pt/Rh20) for use in high-temperature glasses.
   The glass fibre production line was designed in such a way that new concepts and ideas can be tested quickly. The modular design allows a high flexibility, the induction system a significantly faster operability.
   Research and development projects can therefore be carried out faster and more cost-effectively.
    
2. DrapeCube - Forming of textile semi-finished products
   The DrapeCube offers a cost-effective design for the production of fibre preforms from textile semi-finished products. It is used in the production of preforms for prototypes and in small series and is suit-able for companies active in the production of fibre-reinforced plas-tics (FRP).
   In the production of FRP components, the preforming process de-fines a large part of the subsequent component costs. In small- and medium-sized enterprises, this process step is often still carried out manually. This results in high quality fluctuations and component prices. Especially in the case of highly stressed structural components, the fluctuation in quality leads to oversizing of the components.
   Thus, the lightweight construction potential of fiber-reinforced plastics is underused. One solution is offered by the stamp forming process adapted from the sheet metal forming industry for shaping rein-forcing textiles. The textile is inserted between two mould halves (male and female) and automatically formed. Due to high plant and tooling costs, this process is used almost exclusively in large-scale production.
   The ITA has developed the DrapeCube forming station which offers a cost-effective alternative and is able to completely reproduce the current state of the art for forming textile half branches. The process steps will be demonstrated in a video at the booth.
    
3. Carbon fibre reinforced plastic (CFRP) preform
   The CFRP preform consists of carbon multiaxial fabrics formed by expanded polystyrene (EPS) to optimise draping quality. Preforms of increased quality can be produced by gentle, textile-compatible forming with foam expansion. For the first time, foam expansion was used to form preforms in such a way that the draping quality is improved compared to classic stamp forming.
   The advantages of the CFRP preform lie in the savings in plant costs, as the investment is much lower. In addition, the proportion of waste is reduced because near-net-shape production is possible. In addition, rejects are reduced, as fewer faults occur in the textile.
    
4. Embroidered preform with integrated metal insert
   The 12k carbon fibre rovings are shaped into a preform using Tai-lored Fibre Placement (TFP) which is a technical embroidery pro-cess. For the further layer build-up, a fastener is not only integrated under the roving layers but also fixed by additional loops. The highly integrative preforming approach offers the possibility of reducing weight and process steps as well as increasing mechanical perfor-mance.
   Until now, inserts were glued or holes had to be drilled in the com-ponent. Bonded fasteners are limited by the adhesive surface. The bonding of fasteners into drilled holes results in high drill abrasion and thus high tool wear.
   The advantages of the embroidered preform with integrated metal fasteners are the reduction of scrap due to TFP preforming and the increase in the specific pull-out force. In addition, it is possible to automatize the production of integrative preforms. This makes the preform with integrated metal fasteners interesting for the automotive and aerospace industries.

The Aachen Center for Integrative Lightweight Production (AZL) of RWTH Aachen University is installing a new ENGEL injection molding system in its technical center. Engel Deutschland GmbH – in cooperation with the ENGEL Centre for Lightweight Composite Technologies in Austria – will install the 2-component injection molding system with turning plate and 17,000 kN clamping force in 2019. This machine setup is the basis for further developments of efficient inline-combination technologies using different kinds of polymer performance materials.

The ENGEL injection molding system will enable innovative combinations of already established fiber-reinforced plastics (FRP) processes and the development of new individual processes. The focus is on increasing resource efficiency in lightweight production. With the new equipment, new research and development initiatives can explore the more efficient use of materials, which are eventually the key to the mass production of lightweight components. The research will address multi-material systems, continuous processes, process chains as well as self-optimizing processes.

Dr.-Ing. Michael Emonts, Managing Director of the Aachen Center for Integrative Lightweight Production (AZL) is looking forward to realizing new innovative lightweight production process with the new injection molding system: “This new injection molding system offers us as specialists for lightweight production technology in cooperation with the injection molding experts of the Institute of Plastics Processing – the IKV – the opportunity to establish hybrid processes for industrial lightweight applications. The system will expand our existing machinery in the AZL Technical Center and will be available as an important platform for lightweight production research at RWTH Aachen University.”

Being a Partner of the AZL, ENGEL has already been working closely with the AZL for many years as a Partner Company of the AZL Partner Network. Dr. Stefan Engleder, CEO of the ENGEL Group, emphasizes the importance of close collaboration with technical universities and especially with the AZL: “The AZL provides great conditions for industry-related research activities in the field of lightweight composites as it is characterized by a strong interdisciplinary approach. It benefits from the great infrastructure and the collaboration with well-known institutes of the RTWH Aachen University. ENGEL is looking forward to working together with the AZL on developing efficient lightweight composite mass production processes.”

In addition to the numerous composite and lightweight equipment at the RWTH Aachen Campus, the AZL Technical Center comprises large-scale equipment for the development of processes for lightweight production, such as a composite press from Schuler Pressen GmbH with 18,000 kN clamping force.

For Schoeller Summer 2020 everything flows smoothly. The fabrics move with a fluid lightness in a closed ecological cycle. Upcycled products with ECONYL® yarn and the PFC-free ecorepel® Bio technology based on renewable raw materials are two ecological highlights of the 2020 Summer Collection, which is being developed and produced in the heart of the Swiss mountains. Color effects turn the functional textiles into exciting multicolors with contrasting reverses and fresh, modern plain colors that can easily be combined.

REGENERATED ECONYL® YARN
The textiles manufactured by Schoeller using ECONYL® yarn made from regenerated material are genuine upcycled products. The ECONYL® Reclaiming Program of Aquafil S.P.A. reduces global waste by collecting recyclable materials from landfill sites and the world’s oceans and returning them into the production cycle. The resulting yarn is no different from conventional textiles in terms of quality and appearance. The Schoeller fabric family with ECONYL® yarn encompasses a complete package with diverse exciting qualities such as ultra-light, bi-elastic schoeller®-dynamic (e.g. for windbreaker blousons), very soft, fine schoeller®-dryskin (e.g. for high-tech shorts) and lightweight schoeller®-WB-400.

ECO-CREATED
New, supersoft soft-shells with ECONYL® yarn are available with different backings and weights depending on the situation. The lightest schoeller®-WB-400 radiates a sense of summer in fresh tones such as melon, oxygen blue or khaki with a smooth jersey reverse in contrasting colors, also made from ECONYL® yarn. A slightly heavier quality surprises in classic black with an elegant, navy blue reverse, while the Bordeaux nuance of the soft-shell with its brushed reverse in stone grey feels warm, soft and cozy. The fluorocarbon-free ecorepel® bio-technology, based on renewable raw materials, offers sustainable water repellence.

WHITE MATTER
The dominant features of summer 2020, alongside sustainable textiles and technologies made from natural materials, are inspired multicolors. The comfortable, multicolored schoeller®-WB-400 qualities produce completely new color effects and create a cheerful look – both for outdoor activities and in urban sportswear. The combination of melon, ocean green and stone grey with white changes the mood of the original colors and lends the textiles an unexpectedly chalky, summery look. Another striking feature is the lightweight, white jersey backing, which is only revealed at second glance.

AUGMENTED ORIGINALS
The presentation of the authentic schoeller®-dynamic qualities is no less lively, ranging from mossy green tones and blue nuances through to the brown variations of tree bark. The multicolors combine perfectly with plain fabrics and are impressively functional thanks to the PFC-free ecorepel® bio-technology, which also provides reliable water repellence. The basic qualities of the lightweight schoeller®-dryskin trousers and jackets are given a touch of elegance in the form of a discreet sheen and fashionable colors. In soft blues and greens, these supple all-rounders are highly wear resistant and offer ideal moisture management through the microfibers on the inside. They also feature ecorepel® bio-technology for water repellence.

•    New, sustainable, ready-to-use solutions for plastic auto parts to support China’s electric vehicle boom
•    Stronger, softer nylon polyamide fibers plus fast processing for clothes, carpets & industrial applications
•    AddWorks blends lower total cost of ownership & reduce production complexity while enhancing performance

Muttenz, May 3, 2018 – Clariant, a world leader in specialty chemicals, introduced new additive solutions for plastics materials at Chinaplas 2018.

“Our innovations focus on higher performance at better convenience for a sustainable future,” says Stephan Lynen, Head of Clariant BU Additives. “At Chinaplas 2018 we demonstrated our technical and market capabilities around the theme of e-mobility. The immense changes in mobility call for lighter, safer and smarter vehicles. We offer new additive solutions, such as AddWorks, and technical capabilities to respond to this demand. We are accompanying this with a series of investments such as new production facilities in China.”

Clariant’s new AddWorks solutions – AddWorksATR 146, AddWorks LXR 568 and AddWorks TFB 117 – are specifically aimed at improving performance and efficiency of plastics materials for compounders, polymer and fiber producers in China’s major plastics manufacturing segments. All three solutions are part of the globally available portfolio.

The full AddWorks portfolio consists of differentiated market-specific synergistic additive blends that streamline production processes and create value for customers while enhancing performance. Each solution is customized to specific market needs, underlined by broader considerations such as emission reduction, and less energy and resource usage.

Sustainability and performance for the world’s largest auto market
To support the significant investment in electric vehicles in China, Clariant launched two additive innovations that improve the lifetime of lightweight automotive parts and under-the-hood applications and reduce VOC emissions in an easy to use single solution.

AddWorks ATR 146 is a new low dosage, sulfur-free heat and light stabilizer for filled polypropylene (TPO) compounds used in interior applications. Its exceptional heat and light stability and long term color retention offers the automotive industry unmatched performance. It shows no surface cracking after 700 hours at 150°C, which enables dashboards, instrument panels, door panels and pillars to maintain their aesthetics longer than with traditional stabilizers. It also contributes to reducing blooming and VOC emissions, supporting the common effort to make automotive interiors healthier and odorless.

AddWorks LXR 568 is a high performance processing stabilizer that helps to prevent plastic resins, especially polyolefins, from degradation at high processing temperatures. For the automotive industry, this reduces the tendency of injection molded polypropylene interior car parts to turn brittle during heat exposure, enabling them to maintain a defect-free surface. It also has low migration and low fogging that support healthier in-cab environments.

AddWorks LXR 568 combines outstanding color and melt flow protection with good resistance to hydrolysis and high thermal stability. This makes it ideal for interior and under-the-hood powertrains and wider application areas such as packaging films. It is available in free-flowing pills and micro-pills which are easy and convenient to use.

Softer, stronger polyamide fibers for clothes, carpets and industrial applications
Within the next three years, China is expected to account for 40% of the world’s nylon production and more than 30% of the nylon resin consumed globally[1]. The new AddWorks TFB 117 offers a number of benefits to help stabilize and smoothen fiber production processes, protect color, and improve heat stability and mechanical properties of fibers. AddWorks TFB 117 ensures smooth spinnability with less filaments breakage, even at low processing temperatures and at high speed spinning up to 5,500 m/min.

Martin P. J. John, Head of BL Performance Additives at Clariant, comments: “AddWorks solutions are an ideal fit with China’s priority of achieving more sustainable production. They save time and reduce complexity along the production process, with easy to use formats that reduce health risk and chemical waste. Our new state-of-the-art production facility in Zhenjiang, China, which opens later this year, is dedicated to the manufacturing of AddWorks to deliver innovative solutions tailored to the needs of the market. Made for China in China.

In addition to AddWorks, Clariant presented Exolit® OP 1400, a highly stable non-halogenated flame retardant enhancing safety during the charging process. It also provides outstanding thermal stability for under the hood applications. Exolit OP 1400 has been awarded the Clariant EcoTain® label for outstanding sustainability and performance.  

Clariant also introduced two ranges of performance waxes that smoothen the production of automotive plastics for under the hood applications, Licowax® and Licocare® RBW. The recently launched Licocare RBW is a series of multi-purpose additives based on crude rice bran wax. They offer better shaping flexibility, better mechanical properties and enhanced surface finish, which results in a reduced rejection rate and a more effective dosage.

Wielsbeke, Belgium – February 26, 2018 – Beaulieu Fibres International, the leading European polyolefin fibre producer, is once again the proud recipient of a “Distinguished Supplier” European Supplier Award from Yanfeng Automotive Interiors (YFAI). It is the second year in succession that the global leader in automotive interiors has recognised the significant expertise and support provided by Beaulieu Fibres International.

The very close cooperation between the two companies in 2017 enabled YFAI to successfully develop its latest generation of lightweight door panels, helping to further reduce weight. The technical team at Beaulieu Fibres International worked closely with YFAI’s development team to achieve this important step forward for the automotive industry.

Beaulieu Fibres International was presented with the award at YFAI’s annual European Supplier Award ceremony held this year on February 7th at its European headquarters in Neuss, Germany.

A total of 15 suppliers providing plastics, resins, chemicals, foams, trim and metal components received the European Supplier Award in various categories in recognition of their outstanding performance in 2017. Suppliers are rated on the factors of quality, cost, customer satisfaction, development, technology and innovation, and service.

• Metallic sheen and concealed safety

Net-like structures, metallic sheen, concealed safety, naturally-warming fabrics with Nilit® Heat yarn made of coffee charcoal and PFC-free bio technologies based on renewable raw materials are just some of the highlights of the Schoeller 2019/20 Winter Collection, developed and produced amidst the mountains of Switzerland. Color effects create metallic surfaces on functional textiles and exciting multi-colored looks with richly contrasting reverses.

METALLIC SHINE

The new schoeller®-spirit qualities provide grand style in winter 2019/20. The softly-flowing warp-knitted goods play with transparency and metallic looks. In forest green, silver or copper and aluminized reverse, this season’s  showpieces are also reflective. This play with light continues in the crosswise elastic lightweight with a reflecting dot design. This cool print with concealed safety in two-tone silver grey or khaki green ensures outstanding visibility at twilight. Additional water repellence is provided by the fluorocarbon-free ecorepel® Bio technology, based on renewable raw materials.

WARM FABRICS

The new schoeller®-dryskin qualities ensure a pleasantly warm body climate in winter 2019/20. Thanks to the insulating Nilit® Heat yarn on the interior, which captures and stores the body’s own heat, these fabrics warm the wearer naturally. This unique yarn produced using coffee charcoal posseses antibacterial properties and offers maximum clothing comfort at winter temperatures. The focused pants and jacket qualities in a variety of weights in fresh mandarin, deep aubergine, petrol or light stone also impress with their high abrasion resistance, ideal moisture management and reliable water repellence thanks to PFC-free ecorepel® Bio technology. The same natural heat retention is offered by the cozy schoeller®-naturetec in washable, mulesing-free wool and ecorepel® Bio in dark petrol, navy or rust.

MULTI COLOR

In addition to sustainable fabrics and technologies, winter 2019/20 is dominated by multi-coloration. The highly-elastic multi-colored schoeller®-prestige and schoeller®-dryskinqualities lead to completely new color effects and nuances. Ever-changing, exciting effects result from beautiful mossy greens and dark blue and grey variations to burnt henna and chocolate color combinations. Always with a contrasting color on the reverse, they are real eye-catchers which of course also impress in functional terms. In addition, the schoeller®-dryskin qualities are finished with the PFC-free ecorepel® Bio technology.

Nilit® Heat is a registered trademark of NILIT Ltd.

The AZL will continue its collaboration on composites in buildings and infrastructure after completing an initial market and technology study which identified new potentials for composite technologies in buildings and infrastructure markets. The aim of the new AZL Workgroup which will meet for the first time on January 25th, 2018 is to jointly develop new applications and to support the business development for composites in these two growing markets. The meeting is open to interested companies from the composite industry as well as the building and infrastructure markets.

The aim of the initial workgroup meeting will be to turn insights from the study into a long-term workgroup collaboration and to define topics and initiatives for the joint cooperation in the field of process and manufacturing technologies, fire safety regulations, materials as well as standards and norms. Industrial keynote presentations will introduce these action fields and will provide an insight into building and infrastructure applications for composites. The meeting will furthermore provide a platform to network with companies along the entire composite value chain.

Dr. Amer Affan, CEO and founder of AFFAN Innovative Structures based in Dubai is in charge of various composite projects for buildings such as the Museum of the Future in Dubai: “We have been utilizing structural composites in construction since 2010. Composites is a truly high-tech material compared with the traditional building materials (steel, concrete, timber and aluminum) but it is still to be recognized as such in the conservative and price-sensitive building industry. AZL, particularly its location at the RWTH Aachen University and its partner companies, offers a good platform to progress the use of composites in construction.”

AZL together with more than 25 companies just completed the Joint Market and Technology Study on “New Potentials for Composite Technologies in Buildings and Infrastructure” establishing a broad knowledge on business opportunities for composite technologies in these two growing markets. In a structured approach, the study determined the key segments as well as the technologies/applications with the highest market and technological potential. Analyses of 20 market segments, investigation of 438 applications, technology analyses of 25 highlight components and 11 detailed business cases were elaborated throughout the study. Additional to requirement analyses for materials and production technologies, new concepts for efficient profitable production technologies and cost engineering analysis were developed. With the workgroup, the AZL will take this initiative a step further with the aim to build a long-term cooperation platform for composites in buildings and infrastructure markets.

Justin Jin, CEO of the Korean company AXIA Materials participated in the study and is part of the AZL Partner Network: “As producer of large thermoplastic composite sheets and composite SIP (Structural Insulated Panel), we are eager to drive composites in B&I applications with the best efficient way. The AZL study on Buildings and Infrastructure provided us a great networking with key players in this business field and opportunities to strengthen our products with the key elements from partners. The study also gave us a proper market understanding including market size/volume in numbers to prove the value of this technology to building industry. We are looking forward to following up on these first insights and to realize applications with the AZL and its partners.”

Besides the networking options, the meeting will offer the opportunity to get an insight into the activities of the AZL Network consisting of nine research institutes at the RWTH Aachen Campus and more than 80 companies from 21 countries. During an optional guided tour, participants will visit selected institutes at the RWTH Aachen Campus. The meeting is open to all interested companies and free of charge.

More Information on Meeting and the Study
Information on AZL activities in the field of buildings and infrastructure:
www.azl-lightweight-production.com/composites-buildings-infrastructure
Details and registration to first Workgroup Meeting on January 25th, 2018:
http://www.azl-lightweight-production.com/termine/1st-workgroup-meeting-buildings-infrastructure

JEC Group is launching the first ever book on the growing use of composites in architecture: “The Future of Building: The Growing Use of Composites in Construction and Architecture”. Its 194 pages of information and 80 concrete examples demonstrate the advantages of composites: lightweight, durable, resistant to corrosion, inexpensive to maintain, flexible design etc. “Composites are playing an increasingly bigger role in construction! Between 2016 and 2021, we are expecting a sharp growth in the market and a 5 to 6% annual increase in the use of composites in this sector,” explained Ms. Frédérique MUTEL, JEC Group President & CEO. “This new book supports JEC Group’s strategy towards end users. Composite materials offer tremendous advantages for architects and designers and, for the first time, they are the subject of a book that demonstrates the performance of composites in the construction and furniture industries,” said Ms. Anne-Carole BARBARIN, Development Director at JEC Group.