Polyethylene would be an ideal material for lightweight construction, it’s energy-efficient, can be made from renewable raw materials and is almost residue-free recyclable, unfortunately, only Polyethylene components that are reinforced as composites for example with carbon or glass fibres are truly mechanically resilient.

Both Polyethylene and Polypropylene account for over half of all polymers produced worldwide. Polyethylene is found in many of the plastic products used every day and as a pure grade material, it’s infinitely reusable with the used products melted down and formed into new components with consistently good quality. Polyethylene is heated and converted back into raw materials that go back into the chemical industry or into building blocks for the production of hydrocarbon materials completely without residue. For this reason and because of their low weight, hydrocarbon materials are ideal for sustainable lightweight construction.

Up to this point, however, it hasn’t been possible to manufacture load-bearing components from regular Polyethylene because on its own it is not a strong enough material. Traditionally fillers like carbon or glass fibres have been used for reinforcement.

The addition of fillers does have a negative impact on the cost and the energy, raw material, environmental balance: production and recycling are considerably more difficult and expensive. So-called ultra-high molecular weight Polyethylene or UHMWPE for short, used as a high-performance material in medical implants such as acetabular cups or knee joints, offers an alternative. However, this pure, high-strength and abrasion-resistant material cannot be processed by injection moulding: It has to be pressed into a mould as a powder, sintered and then milled into the exact component in a complex and cost-intensive process. Although UHMWPE fibres can achieve the strength of steel, they are expensive and unsuitable for material recycling.

In the SusCOMP project, we carried out research on All-PE single component composites that can be processed by injection moulding and directly reinforce themselves. Of course, we were particularly interested in the mechanical properties of these composites. DSM already spins high-performance fibres from long UHMWPE molecular chains that orient themselves along the fibre direction, so-called “Dyneema” fibres. It would be technically possible to incorporate such fibres into PE as reinforcements, but this would involve a great deal of work and expense and would not be suitable for material recycling Raimund Jaeger, leader of the Polymer Tribology and Biomedical Materials group at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg

Prof. Dr Rolf Mülhaupt and his team at the Freiburg Materials Research Centre at the University of Freiburg found the solution to this challenge by finely distributing different catalysts, which can be used to produce PE in different chain lengths, along with the same catalyst carrier. In the subsequent synthesis of PE using ethylene polymerization, mixtures of low, medium and ultra-high molecular weight PE, known as reactor blends, are simultaneously produced on this catalyst.

With this trick, PE blends are produced directly during polymerisation that can be injection moulded without any problems, explains Prof. Dr Mülhaupt

The process avoids high viscosities, which are normally a challenge when a high proportion of UHMWPE molecular chains are to be processed in injection moulding. High shear currents, which occur during injection moulding in narrow injection moulds, cause fibre-like UHMWPE structures to form from the ultra-high molecular weight fraction via self-organization of the material. These fibres reinforce the composite and even orient themselves in the desired direction during injection moulding, thus ensuring mechanical stability. These components are also easy to recycle.

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The scientists at the Fraunhofer IWM tested samples of this new high-performance material for their material properties. The mechanical properties show: many applications are conceivable, for example, long furniture parts as well as rail and shutter guides or parts for car interiors. In addition to their low weight, the components also have the advantage that water-based lubricants are very well tolerated.

The follow-up project, 3D-SusCOMP, now involves processing the material using a 3D printer. Previously, the good properties of All-PE composites could only be achieved if the polymers were oriented when injecting them into a narrow mould. However, the reinforcement by self-organization exclusively occurs in the direction specified by the moulding tool. This is already a major step forward, but other component shapes and composite materials, so-called multidirectional composites, are also desirable. The scientists found out: the fibre structures also form in the nozzle of a 3D printer. In contrast to injection moulding, however, their orientation in the component can be controlled by the movement of the print head. As a result, many new applications for this recyclable material are conceivable: in addition to lightweight gear wheels in automobiles or for the food industry, it is also possible to produce robot grippers which adapt to the shape of a part, medical orthotics or connectors from a “single mould”.

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The construction consists of a glass-filled thermoplastic PET which is combined with continuous glass fibres added in the 3D printing process, this unique combination offers high strength with extreme versatility and sustainability.

Sensors built into the design enable them to build a digital copy, these sensors can also predict and optimise maintenance, ensure safety and extend the life span. It can also incorporate new functionalities such as monitoring vital environmental aspects and improve the decision-making process for maintenance and inspection via dynamic real-time reports on the condition of the bridge.

FRP bridges are already known for having a longer life expectancy with lower life cycle costs compared to steel bridges. What’s new here is the use of a 3D printing technology, enabling us to print large scale continuous fibre reinforced thermoplastic parts. Using this new composite thermoplastic material, we will be ushering in a new era for sustainability and push the boundaries of bridge functionality even further. Maurice Kardas, Business Development Manager at Royal HaskoningDHV

In future, it’s hoped this technology will lead to more efficient bridge designs helping to deliver an optimised printing process which results in improved mechanical performance.

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The new company, which will have sales of more than $2 billion a year and employ 1,950 employees will be 65% owned by CVC, with DSM having the remaining 35%. The deal will result in DSM recognising a first quarter loss of €130 million but will receive net cash proceeds of over €300 million.

DSM sees the proposed transaction as a logical step into its overall strategy. The company feels that its Composite Resins and Polymer Intermediate activities no longer fit into its portfolio and the partnership with CVC will allow them to fully focus on the Nutrition, Performance Materials and Innovation activities complemented by accelerated actions to reduce costs.

CVC will work with current management of these businesses to make the new company a success. The investment company sees these businesses as a solid platform with leading positions and substantial potential for future growth. As a 35% shareholder in the new business, DSM will be able to benefit from any improvements.

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Steel and aluminium alloys have long been the materials of choice when manufacturing car wheels. However, unlike composites these materials are prone to corrosion, are heavier and can’t be further optimised to reduce weight without sacrificing safety.

At just 5.2 kgs ESE say these are currently the lightest production carbon wheels on the market today. The company say that with the unmatched strength and stiffness to weight ratio, these wheels reduce the weight of vehicle which give the car better handling, a quieter and smoother ride, faster acceleration, quicker deceleration and improved fuel efficiency.

The E1 wheels are made using ESE Industries’ Next Generation Autoclave Process (NGAP), which combines high-speed autoclave cure with the low viscosity of the resin to achieve very low de-moulding times. The NGAP technology has all the advantages of autoclave manufacturing with a mass production approach to deliver carbon fibre composites at a price that’s not currently possible with any other production method.

The wheels are available to order from the ESE website and start from $2,000

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Euroresins distributes products to the composites industry with activities in nine countries in Europe, including the United Kingdom, Italy and France. Euroresins realises sales of approximately €90 million with around 70 employees. All employees will on the closing date transfer to the new owner.

Cathay Investments is the UK holding company for a group of companies engaged in chemical distribution and trading. Cathay’s principal trading business is Cathay Composites, which distributes glass fibre, resins and other composite materials throughout the UK and Scandinavia. Since its establishment Cathay has grown its portfolio to six companies.

The sale of Euroresins is in line with the strategic actions DSM is pursuing for Composite Resins, as announced in November 2014. Subject to customary approvals and notifications, the transaction is expected to close in Q1 2015. Financial details will not be disclosed at this time.

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The new system is based on DSM’s 40% bio based, styrene free, cobalt free resin system. The company say that the use of this resin brings faster resin infusion and requires only limited post-cure. The system also incorporates 3B’s glass rovings. Through an optimised sizing applied on the glass filaments an excellent fibre/ resin interaction is obtained, resulting in improved composite properties for a long-lasting blade operation.

The new system has received the 2014 Innovation Award from JEC in the Sustainability category, ,” explains Karsten Schibsbye, Manager Next Generation Blade Project, Siemens Wind Power.

For Siemens the new composite system provides many benefits, including a major reduction in blade manufacturing cost and an increased process output

The post Companies Team up to Develop new Composite Wind Turbine Blade System appeared first on Composites Today.

The low panel weight resulted in a fast and easy installation. In addition, the specific shape of the panels will contribute significantly to the low energy consumption of this energy neutral building.

DSM, composite manufacturer NPSP Composieten, and specialty resin supplier Büfa have introduced composite façade elements with large sizes that can be mounted in a very short period of time. In collaboration with construction company BAM more than 100 of these elements were installed on the new office of energy company Enexis in Zwolle (Netherlands).

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Façade elements made from composite materials have a significantly lower weight than their counterparts in concrete (in this specific case less than 10% of the concrete equivalent). Because of their low weight and a specially developed and patented aligning anchor/ hook system, the panels could be mounted in only 5 min per panel.

The panels were manufactured with a vacuum infusion process based on DSM’s Synolite 1967 resin, Büfa’s Firestop 6815-N-3 resin/ S272-SV gelcoat, and a PUR foam core. The inherent design flexibility of composites enables manufacturing of components with unique shapes. The panels used for the Enexis building are reflecting sunlight because of their specific shape and prevent heating up of the building in summer. Also, because of their excellent insulating properties they keep the heat inside in winter.

Photo by: Ben Vulkers

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Beyone 1 resin is styrene as well as cobalt-free and contains approximately 40% of the raw materials based on renewable resources. This resin is targeted at applications in Building, Infrastructure, Marine and Wind energy.

The low resin viscosity enables easy impregnation and high processing speeds, saving cost and yielding high process output. Close to 40% of the raw materials used for this resin are derived from renewable resources, diminishing considerably the ecological footprint and already clearing the way for continued supply in future when availability of fossil-based raw materials may be reduced.

DSM have also introduced two resin systems for the manufacturing of components and structures through vacuum infusion at high-speed, called Daron 90/B18 and Daron 135/B5 DSM claim these new resin systems allow part manufacturers to reduce production cycle times, and make strong parts with excellent durability and resistance to fatigue. Target markets include Wind Energy, Building & Infrastructure and Marine.

Because of their low inherent viscosity and compatibility with multiple fibre sizing types, glass impregnation with Daron 90/B18 and Daron 135/B5 resin systems is straightforward. The curing can take place at room temperature and is fast. Unlike comparable epoxy resin systems, a great through cure can be achieved by applying only a limited post-cure. The Daron® 90/B18 and Daron® 135/B5 resin systems can give excellent static and dynamic properties both with glass and with carbon fibres.

The market for large structural composite parts has been dominated by epoxy resins for their good fatigue resistance (in spite of epoxy processing limitations and part manufacturing inflexibility). Unsaturated polyester and vinyl ester systems do provide significant processing benefits and with these new resin systems DSM claim to offer the best of both worlds, allowing parts with great mechanical integrity and fatigue resistance to be made at high-speed and low-cost.

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Fons Harbers, EMEAI Sales Director says that the prices rise is down to the continued increase in costs for key raw materials.

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This new product (Daron 220) can be easily tuned for a variety of applications, and used as single resin or as part of a two-component system. Because of its low viscosity, glass fibre impregnation is straightforward. This allows making components with great strength, both with glass and carbon fibre. Moreover, the parts can demonstrate excellent heat resistance.

When used as part of a two-component system the glass transition temperature of the resin can be as high as 220 °C, way above the glass transition temperature of conventional Vinyl ester resins. The chemistry of the resin enables running pultrusion lines at much higher speed vs. traditional high heat epoxy resins.

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