From the Sector

The two AZL Partners Conbility GmbH and Fraunhofer IPT, Aachen started their long-term cooperation for the further development and for the commercialization of Fraunhofer´s tape-placement and tape winding systems with in-situ-consolidation by the usage of laser or IR heat sources.

With this cooperation, the company Conbility GmbH makes 25 years of expertise in special machine development of tape placement systems of the Fraunhofer Institute for Production Technology IPT commercially available. Conbility offers two different tape processing systems available in different configurations.

The “PrePro 2D” machine system allows for the automated tailored tape placement of UD laminates and which can be used for subsequent thermoforming or as stiffening structures in injection molding processes. The machine comprises a rotating and translational table which is moved relatively to the applicator station. The table is scalable according to the requirements of customers. Standard table diameters are 1200 mm or 2000 mm. The applicator station can be equipped with a single or with multiple spool applicators. Because of the large process area, a 9 kW IR heater is used for the in-situ-consolidation process.  
Three in one: Three technologies included in one single modular system
Furthermore, the award-winning “PrePro 3D” tape placement and winding applicator is available as modular product with decentral control system (including closed-loop control of energy input into the processing zone) for the “plug-in” implementation in existing robot systems or machine systems by standard interfaces for the communication with the master control system. Conbility provides the single applicator as well as turn-key ready systems including the robot and handling systems.

Unique selling point of the PrePro 3D system is its multifunctional range of usage: it accomplishes laser-assisted thermoplastic tape placement, IR-assisted thermoset prepreg placement and dry fiber placement: Three technologies included in one single modular system.  

During the JEC World in Paris (March 6th – 8th 2018), Conbility GmbH will present its new “VCSEL Tape Placement and Winding Applicator” (Fig. 3), developed in cooperation with Fraunhofer IPT and Philips Photonics at the AZL Composites in Action area (Hall 5A, C55).

VCSEL Laser Systems as heat source for lower investment and process costs
This applicator uses an integrated VCSEL Laser System as heat source which has been developed by Philips Photonics. This tape placement and winding applicator can also be integrated as modular “plug-in” system into industrial jointed-arm and linear gantry robots in variable manufacturing cells. Using the new VCSEL Laser as heat source (VCSEL: Vertical-Cavity Surface Emitting Laser) leads to significant lower investment and process cost in comparison to other laser systems. Furthermore, the VCSEL laser system can accomplish controllable in-process adjustments of the laser-spot geometry as well as the intensity distribution within the spot size during the process (in-process control of laser-spot geometries and intensities) for the first time. The new system with 2 kW laser power and 10 separate emission zones which can be controlled separately will be shown at JEC World in Paris 2018 as new product of Conbility GmbH.

At JEC Asia 2017 (1-3 November), the international textile group CHOMARAT will receive a JEC Innovation Award in the Sports & Leisure category for its C-PLY™ Hexagonal with visual & structural stitching. “CHOMARAT provided NEILPRYDE and COBRA with its C-PLY™ Non-Crimp Fabric (NCF) technology to help them manufacture an innovative windfoil board, and we are very proud to be rewarded with our partners”, says Pascal JOUBERT DES OUCHES, Sports Equipment Market Director at CHOMARAT.

C-PLYTM HEXAGONAL COMBINES NEW CARBON LOOK AND PERFORMANCE

The unusual stitching of this carbon multiaxial NCF reinforcement combines visual appeal and mechanical performance. C-PLY™ Hexagonal is an innovative carbon NCF with a unique stitching yarn designed to be visible within the resin and to capture resin colour pigments. The stitching yarn also improves fracture toughness compared to standard NCF.
“We researched the right stitching yarn among multiple options before coming up with a tailor-made yarn solution. C-PLY™ Hexagonal provides a unique honeycomb carbon design that appeals to end users”, adds Philippe SANIAL, R&T Director at CHOMARAT.

A WIDE RANGE, FROM AERONAUTICS AND AUTOMOTIVE TO SPORTS & LEISURE APPLICATIONS

Originally dedicated to the design of aerospace and automotive parts, the concept is now successfully applied to the sports & leisure sector. In this innovative windfoil board construction, tows are spread to create thin plies, which are then stitched with precise ±45° angles. The C-PLY™ NCF structure respects the fibre alignment and is optimized in terms of fibre angles and ply weights, thanks to unique spreading technology. The result is a leading-edge carbon NCF reinforcement allowing structural design benefits, premium surface quality and overall parts cost savings. “Bringing a new carbon visual signature for our high-performance C-PLY™ range of NCF is a key to boost retail sales in the whole sports & consumers product industry”, concludes Pascal JOUBERT DES OUCHES.

Composites use in Building and Construction will be highlighted at JEC newest event dedicated to this specific Composites Industry next month in Chicago, IL, USA. The numerous and diverse benefits that these innovative materials bring to the Building Industry will help overcome the coming challenges such as, urbanization, increase of natural disasters (floods, storms, tsunamis, earthquakes…), along with the decrease of non-renewable raw materials and the high standard levels set by the society in terms of lightness and fluidity. Composites Materials bring answers and opportunities to tackle those issues in sustainable, durable and reliable manners. Solutions like ease of fabrication (Owens Corning), structures durability (Biteam), anti-seismic reinforcement (DowAksa), use of end-of-life products such as recycled bottles of water (Premier Composites Technologies), aerial forms (Optima Projects Ltd) or again energy saving (Armageddon Energy).

Following its strategy to address every Composites End-user, the JEC Innovation Awards will reward these 6 Composites Innovators in Building & Construction that will change the way we build.
If the majority of submissions relied on glass fibers, which is common in the Construction field, we see an increased interest in carbon fibers, especially for structural applications. And similarly to all sectors of the composite industry, thermoplastics are gaining in importance in Construction. Therefore, to promote the growing use of composites as a construction material, 6 categories are awarded, covering a large panel of applications and possibilities.