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First Generation of Vinyl Composites with Long and Continuous Fibers First generation of vinyl composites with long and continuous fibers 2013 Automotive Composites Conference & Exhibition, Detroit Victoire de Clermont-Tonnerre Market Development Manager SolVin Foreword THE POWER OF INNOVATION « The early history of mankind has been classified by archaeologists into three chronological ages: The Stone Age, the Bronze Age and the Iron Age. Each of this Age is named after the materials technology that was possessed by society. This is recognition of the impact of materials on the welfare, economies, and technologies of societies. Materials are the basis of manufactured goods and the basis of construction. In fact, they are the basis of most technological progress. » Christopher Scott Musso « Beating the system: accelerating the commercialization of new materials » 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Living in the Plastic Age Numerous cultural references in the XXth century to the Plastic Age • In the Cinema: - as early as in 1923 in the movie entitled « The Plastic Age » - in the blockbuster « The Graduate » dated 1967, plastics profile is been raised to the attention of a recent college graduate named Ben (played by actor Dustin Hoffman) • Mr. McGuire: I want to say one word to you. Just one word. • Benjamin: Yes, sir. • Mr. McGuire: Are you listening? • Benjamin: Yes, I am. • Mr. McGuire: Plastics. • Benjamin: Exactly how do you mean? • Mr. McGuire: There's a great future in plastics. Think about it. Will you think about it? • In the music industry: first album of the Buggles group in 1980 entitled « The Age of Plastic ». One single: “Living in the Plastic Age » • In anthropology: a recent research program commissioned by The Smithsonian explored the impact of plastics on contemporary society. 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Contents • LF Composites overview - Market - Challenges • New vinyl engineering technologies • Focus on Process 1 and associated composites • Focus on Process 2 and associated composites • Conclusion: a disruptive innovation 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 LF Composites 1 Market overview 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Current LF composites market led by thermosets… Thermoplastics: PP, PE, PPS, PEI, PEEK, PA, NO PVC to date Market size 12%* Thermosets in 2013 Polyester Vinyl-ester Epoxy 2020 Phenolic Polyurethane • Thermosets represent around 88%* of the composites market. • Unmet needs are: VFast cycle time, allowing large production scale VHigher mechanical properties to replace metal V“Green design”, easy to recycle and valorize scraps and end of life parts • Strong potential for Thermoplastic Composites VMarket pull for thermoplastic composites bringing strong added value in mainstream applications at affordable cost with affordable manufacturing process * Gesstimation, Olivier Wyman study 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Demystifying the composites challenges 1 Build reliable material characterisation database Homologation of min. 2 raw materials suppliers 5 (matrix & fiber) 2 ." ) !!+ ) ta h % # "* ) .5 *" &"%%"! " ! " " ( "" ! " " tw9{/wL.9w{ Enhance predictability of CAE toolset /I![[9b D9{ 4 3 5 !!! " #$ % &"$ të/( Upscale from a pilot line to mass production: 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 New Vinyl Engineering 2 Technologies 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Solvay breakthrough in the composites landscape PVC/ Flax PVC/ Fiberglass Vinyl Fiberglass Reinforcement 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Breakthrough in rigid LF vinyl composites Short fibers mixed with PVC dry blend before Historical being extruded Decking in process Drawback: this process cuts the fibres providing WPC limited mechanical properties to the end products. 2013 1st Process Disruptive Profiles innovation Step 1: Dip coating of continuous fibers reinforcement in a vinyl dispersion Technologies without shear Step 2: Drying and gelation by hot air Car fabrics NEW (No extrusion) prepregs processes allowing for the first time to keep the 2nd Process length of long and 2 Process continuous fibres in Step 1: Dispersion of PVC dry blend into Sandwich vinyl composites. the chopped fiberglass through an panels alternating electric field Motor Step 2: Gelation by hot air and calendering encapsulation 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 First generation of continuous fiber-reinforced vinyl composites C* I$ $,/$$ të//{ Vinyl / t $$ $ Fiberglass sheet Y" &' ( Construction and Automotive C$! !" Vinyl / Fiberglass Ü 5 $& $ tapes Y" &' ( Construction and automotive &$ Vinyl/ flax !" fibers sheet t $ $ Y" &' !$ ( Automotive market 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Focus on process 1: Dip coating of continuous fibers in a 3 waterborne vinyl dispersion 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Dipping of continuous rovings - 1st step: fabrication of a strip • Use of PVC latex to impregnate the fibres • Drying by air flow • Gelation by IR heating 284°F 356°F 455°F UD Tapes or fabrics prepregs 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Experimental dipping line Dip coating Heated tunnel Die 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 UD vinyl-reinforced fiberglass tapes Properties Unidirectional tapes - Lightweight - 20% waterborne PVC dispersion • 25% weight reduction compared to and 80% Fiberglass metal for the same rigidity - Thickness: 0.3 – 1mm - Very high mechanical properties • Tensile Modulus: 45GPa • Tensile Strength: 140MPa Potential Applications - High thermal insulation - Alternative to metal or heavy - in the window profile application (up to 35%) composites reinforcement in either window and door profiles or - Good fire behavior automotive components • Limiting oxygen index > 40% - Good thermo-mechanical resistance • HDT: 90°C - 194°F • Lin. expansion coef.: 7 10-6°C - Easy to process • pultruded, welded or glued 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Semi-finished materials 1. Prepregs Glass Basalt Flax 80% Glass 80% Basalt 50% Flax Tensile modulus GPa 45 45 15 Tensile strength MPa 350 400 190 Coeff. lin. expansion 10-5/K 0.7 0.6 0.7 2. Bar reinforcements 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Zoom: Prepreg of woven long flax fibers Rigid plate of Properties - 50% PVC dispersion and 50% - Lightweight long flax fabrics woven • 50% weight reduction compared to - Thickness: 0.5 – 4mm PP for the same rigidity - High mechanical properties • Tensile Modulus: 12GPa Potential Applications • Tensile strength: 140MPa - Car rear shelves • Impact strength: 4.5J/mm at -20°C - Car interior trims - Good fire behavior - Back of seats • Limiting oxygen index > 25% - Headliner - Good thermo-mechanical resistance • HDT: 88°C - 190°F • Lin. expansion coef.: 12 10-6°C - Highly sustainable • 50% renewable fibres - Easy to process • thermoformed, welded or glued - Good vibration damping properties 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Focus on Process 2 Use of an electrical field to disperse 4 PVC dry blend into chopped fiberglass 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Groundbreaking process 1/2 • The patented FIBROLINE Process is a dry process allowing the impregnation of fiber structures with powders PVC dry blend 0 I . ! { 3 $ 5 Fibres / L Rigid PVC film 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Groundbreaking process 2/2 • The product is pressed in a hot and cold calender to gelate • The sheet (around 0.9 mm) is then rolled no destruction of the fibres fibres randomly distributed into the polymer 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 PVC/long fiberglass composite Rigid plates of Properties - 60% S-PVC and 40% long - Lightweight fiberglass (>5cm) randomly • 50% weight reduction compared to distributed metal for the same rigidity - Thickness: 0.6 – 1.4mm - Very high mechanical properties • Tensile Modulus: 15GPa • Tensile Strength: 200MPa Potential Applications • Impact strength: 14J/mm at -20°C - Car rear shelves - Very good fire resistance - Car interior trims • Limiting oxygen index > 40% - Back of chairs - Good thermo-mechanical resistance - Sandwich panels • HDT: 78°C -172°F - Motor encapsulation • lin. expansion coef.: 20 10-6°C - Easy to process • either thermoformed, welded or glued 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Properties of a vinyl sandwich panel with PVC honeycomb (Nidacell®) • Offers the advantages of : - the PVC • Very good fire behaviour • Easy gluing • Relatively high Young’s modulus - a honeycomb • Lightweight • Formability - a fiberglass composite • Stiffness • Good impact resistance (cold temperature) • Improved fire behaviour 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Conclusion 5 A disruptive innovation Solar Impulse 2013 Automotive Composites Conference and Exhibition - SolVin 02/10/2013 Vinyls into automotive Seating shell and back Artificial leather Strip
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