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Prepreg Technology at Polymer Engineering

Development of modern prepreg materials

Department of Polymer Engineering / Professor Dr.-Ing. V. Altstdt / www.polymer-engineering.de


Prepreg Technology at Polymer Engineering

Prepreg Processing Chain at Polymer Engineering

SYNTHESIS

RESIN
FORMULATION

PREPREG
IMPREGNATION

PREPREG
CHARACTERIZATION

LAMINATE
PRODUCTION

LAMINATE
CHARACTERIZATION

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KapitelFormulation
Resin - berschrift lang

Resin Development for Prepreg Processes

Challenges for novel prepreg resin systems

Optimize tack properties for automated placement


Fast curing at moderate temperatures
Out of autoclave curing
Optimisation of cure induced warpage and shrinkage
Functionalities:
Fire behaviour
Electrical properties
Barrier properties
Improved Toughness

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KapitelFormulation
Resin - berschrift lang

Equipment for Resin Formulation

Chemistry lab for formulation of thermoset resins


Speed Mixer
Curing Ovens
Vacuum Mixing Unit

Dispersion of fillers in nano- and micro scale


High-Pressure Disperser
Ultasound Dispersing

Determination of curing kinetics and


decomposition behaviour:
increasing content
(High pressure) DSC of accelerator
Thermogravimetric Analyzer
Rheology Lab

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Prepreg Impregnation

Pilot Prepreg Plant

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Prepreg Impregnation

Pilot Prepreg Plant


Specification:

Working width: max. 30 cm


Reinforcements: up to 32 UD-Rovings or textile fabric
Matrix systems: solvent free resin systems - app. 10 to 50.000 mPas
Line speed: 1 to 10 m/min
Dimensions: app. 16.5 m x 2 m x 2.5 m (l x w x h)

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Prepreg Impregnation

Pilot Prepreg Plant - Technical Details

2 calanders
(1st station up to 250 C)
4 unwinders for
maximum flexibility

fibre laying coating


unit unit

cooling
B-staging at plate
UD spreading max. 250 C
ial unit
w of mater (incl. IR heating)
flo

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Prepreg Impregnation

Flexible coating unit

comma bar indirect coating

Tmax = 200 C
flow
of mate
rial Tmax = 200 C

backing paper

foulard

fabric

Tmax = 85 C

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Prepreg Impregnation

Prepreg Processing - In-line Impregnation


IN-LINE IMPREGNATION

release liner
fibres
release liner
matrix material
heated
calander calander

coating unit
heating table heating table cooling table

release liner prepreg

Direct in-line impregnation of UD-fibres or low aerial weight woven fabrics.

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Prepreg Impregnation

Prepreg Processing - Off-line Impregnation


OFF-LINE IMPREGNATION

Step 1: Resin film production


release liner

matrix material

coating unit

release liner resin film Bildquelle: 3M

Step 2: Prepreg impregnation


resin film

release liner
fibres
heated
calander calander

heating table heating table cooling table

resin film prepreg

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Prepreg Impregnation

Maximum flexibility - tailoring prepregs

In-line impregnation (possibilities) - exemplary:


reinforcement
(UD / fabric)
paper
resin fabric

resin film in-line impregnation dipped fabric


(from bottom side)

Off-line impregnation (possibilities) - exemplary:

TP foil
] resin film or veil ] resin film
] resin film ] resin film

both sided film impregnation modification by foils or veils

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Prepreg Characterization Dr. Collin GmbH, P300P

Characterization of Prepreg Properties


Aerial Weight
Resin Content
Resin Flow
(acc. to DIN, ASTM and IPC standards)
State of Impregnation
Tack properties

Bildquelle:
Zoltek

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Kapitel - Characterization
Prepreg berschrift lang

Characterisation of Tack Properties


Prepreg-Tack

EP Resin A
EP Resin B

Untested Changeable
prepreg heated probe

Temperature
Prepreg-Tack

Tested
Ageing time prepreg

Tack is a major material property for automated as well as for


manual fibre placement applications.
Temperature

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Laminate Production

Out of Autoclave Curing

Hydraulic Heating Press


Press area: 60 x 60 cm2
Press capacity: 1000 kN
Temperature range:
25 to 250 C

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Laminate Characterization

Non-destructive Testing

Ultrasonic Testing
Quality Assurance
B- and C-Scan Mode
3D Visualization

Micro-CT
max. resolution: 5 m
Porosity
Fibre wetting

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Laminate Characterization

Mechanical Testing Center

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Laminate Characterization

Composite Testing - Mechanical Characterisation

Compression after ILSS


impact

Impact Interlaminar fracture toughness mode I & II

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Laminate Characterization

Dynamic Testing of Composites

7 servohydraulic testing machines. Maximum dynamic load: 40 kN

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Prepreg Technology at Polymer Engineering

Prepreg Processing Chain at Polymer Engineering

SYNTHESIS

RESIN
FORMULATION

PREPREG
IMPREGNATION

PREPREG
CHARACTERIZATION

LAMINATE
PRODUCTION

LAMINATE
CHARACTERIZATION

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Prepreg Technology at Polymer Engineering

How to Cooperate?

Public funded research projects


Contact:
in coopreration with industrial partners
Thomas Neumeyer
Direct industrial cooperation
Thermosets and Composites

University of Bayreuth
Material development Department of Polymer Engineering
Evaluation of processability Universittsstr. 30
95447 Bayreuth
Production of sample material Germany
...
Phone: +49 (921) 55 - 7481 / - 7471
Mail: thomas.neumeyer@uni-bayreuth.de
Bildunterschrift
Chair: Prof. Dr.-Ing. Volker Altstdt
http://www.polymer-engineering.de

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