JEC COMPOSITES MAGAZINE - Issue #73 - June 2012 - 32

awards
Development of innovative carbon fibre-reinforced thermoplastic technologies for mass production cars.
Tokyo University developed two types of low-cost, high-performance CFrTP (carbon fibre-reinforced thermoplastics) prepregs for the mass production of ultralightweight cars which can be manufactured by high-cycle moulding and are recyclable. The first one is a discontinuous CF-reinforced isotropic prepreg and the second one a continuous CF-reinforced prepreg. The matrix resin is mainly PP (polypropylene), but PA (polyamide) is also available. The specially surface-treated CF and modified resins developed for these prepregs provide high strength, energy absorption, formability and recyclability. A full impregnation method was developed to shorten the moulding cycle to a minute. Joining, repair and recycling technologies utilizing thermoplasticity were also developed.

official partner

Automotive
Winner: Tokyo University ( Japan) Partnership Network: Toray Industries, Inc. ( Japan), Mitsubishi rayon ( Japan), Toyobo Co. Ltd. ( Japan) & Takagiseiko Co. ( Japan)

These CFrTP prepregs will reduce the weight of automotive bodies by 40 to 70%. The discontinuous CF-reinforced isotropic prepreg is suitable for complex parts and the continuous CF-reinforced prepreg for primary structure parts such as frames. Their most notable feature is their ductile fracture behaviour without significant delamination. Their tough nature not only brings a high energy absorption capacity but also provides more flexible manufacturing methods for composite structures.

Glass-reinforced composite panels for a monorail train.
The ceiling development started in June 2010 and it was commercialised in February 2012. A sandwich construction made from phenolic/glass prepreg – offering fire retardant properties while delivering the target weight – and PET (polyethylene terephthalate) foam was developed. A vacuum-infused epoxy/glass laminate was used for the moulding process. The ceiling meets british Standard bS 6853 for fire/smoke/toxicity requirements. The seat development started in April 2010 and was then cancelled due to a change in specifications by the client. In order to further reduce weight, a high pressure laminate (HPL) and aluminium honeycomb were introduced together with acrylic resin, which allows higher fire retardant content. The apron door development started in August 2010. It is currently on hold and may be proposed to KL Monorail instead. A sandwich construction made from ATH (alumina trihydrate) or red phosphorus filled epoxy/glass prepreg and aluminium honeycomb was used. The cab mask development started in November 2010, with the first production unit delivered in January 2012. The production is on-going. A sandwich construction made from red phosphorus filled epoxy/glass prepreg and PET foam is used.

Railway
Winner: dk Composites Sdn. bhd. (Malaysia) Partnership Network: gurit gmbH (germany), gurit (Australia), Umeco (UK)

Composite bogie frame made of woven glass fabric/epoxy
This bogie frame for railway vehicles is intended to support heavy static and dynamic loads, such as the vertical load exerted by the body of the vehicle, braking and accelerating loads, twisting loads induced by track twisting and traction loads. The bogie frame accounts for approximately 20% of the bogie weight, therefore reducing weight is essential for lightweight railway vehicle design. The glass/epoxy composite saves 30% weight over the conventional steel frame, corresponding to a 635 kg weight reduction per vehicle, or 6.35 tons for a 10-vehicle trainset. reducing the axle load is a key factor for the railway industry, which aspires to develop high-speed and high-capacity trains. The lightweight bogie system reduces wear on the rails and wheels, which consequently require less maintenance. The lightweight composite bogie system leads to a “rail-friendly technology”.

Exaequo
Winner: KrrI, Korea railroad research Institute (Korea) Partnership Network: KM (Korea) for the manufacturing of the composite bogie frame

32 jec composites magazine / No73 June 2012

JEC COMPOSITES MAGAZINE - Issue #73 - June 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #73 - June 2012