PulPress Technology Economic lightweight construction with composites, based on a new manufacturing process Pitea, June 2017 Ron R. van Hoorn S. Krishnamoorthy et al 1
Agenda 1. Evonik Industries Group, introduction 2. Rohacell PMI (Polymethacrylimide) foam product 3. PulPress Process 2
Evonik Industries Power to create Evonik Industries AG Nutrition & Care Sales*: 4.3 bn Resource Efficiency Sales*: 4.5 bn Performance Materials Sales*: 3.2 bn Services Corporate / Other Business Lines : Business Lines: Business Lines: Personal Care Household Care Comfort & Insulation Interface & Performance Baby Care Health Care Animal Nutrition New Business Development 1 Active Oxygens Catalysts Coating & Additives Coating & Adhesive Resins Crosslinkers High Performance Polymers Oil Additives Silanes Performance Intermediates Agrochemicals & Polymer Additives Functional Solutions Methacrylates Acrylic Products CyPlus Technologies Administrative Services Technology & Infrastructure Regional Platforms Corporate Center Creavis Evonik Real Estate Non-core Other Silica New Growth Business 2 * Fiscal 2016 1 Personal Care - PMD, Houshold Care - PMD, Comfort & Insulation PMD ² Coating Additives PMD, Crosslinkers PMD Public High Performance Polymers Specialty chemicals segments 3
Evonik Resource Efficiency for Composites Addives for composite resin systems: Rheological: Aerosil, Dynasylan, Tegomer Crosslinkers: Vestamin, Vestanat, Jayhawk di-anhydrites, Visiomer Modifiers for thermoset resins: Nanopox & Albipox impact modifiers, Albidur, P84 PI Matrix systems and UD-Tapes: Thermoplastic matrix systems: VESTAMID, TROGAMID and VESTAKEEP UD Tapes: VESTAPE allow significantly shorter cycle times in component production, simpler fusion and higher continuous working temperatures. Calidur : Flame Retardant resin & prepreg system (non-phenolic) Structural foam core: ROHACELL PMI foam: Sandwich structures realize their full potential when their super-light cores prove extreme shear- and pressure-resistance, even at high temperatures as is the case with Rohacell cores. 4
Agenda 1. The Evonik Industries Group 2. Polymethacrylimide (PMI) foam product 3. PulPress Process 5
What is ROHACELL? ROHACELL is a rigid PMI (Polymethacrylimide) foam, used as core material for sandwich structures 6
PMI foam production steps and typical application markets 7
Agenda 1. The Evonik Industries Group 2. Polymethacrylimide (PMI) foam product 3. PulPress Process 8
Degree of design complexity Standard processes to make complex sandwich profile parts are expensive High cost complex shapes Hand Lamination Low cost simple shapes Pultrusion Economic advantage 9
Degree of design complexity PulPress : Ideal solution combining complexity with economic feasibility High cost complex shapes Low cost complex shapes Hand Lamination PulPress Low cost simple shapes Pultrusion Economic advantage 10
PulPress process principle relies on properties of a high temperature core 11
Technology and production Overview: 2013: Project Start 2014: First pilot plant in operation 2015: Plant adapted for commercialization 2016: Start of manufacturing for customized parts 2017: Start of commercial delivery (Q4) Technology & production ready: Proof of series production capacity Narrow part tolerances; excellent part properties Realization of high complexity grades 12
Geometric complexity All fundamental geometries can be produced by PulPress : 1. Global radius 2. Local radius 3. Stamping 4. Cross section / geometry 1 2 4 5 5. Distance d 6. Combinations of the above 3 d Assessment of different types of fundamental geometries completed 13
Load carrying capacity Performance validation: Static loads - Buckling 50-75% Sandwich design Hollow CFRP design Hollow pultruded profile PulPress technology Testing method Significant increase in buckling load through sandwich design in PulPress technology 14
Performance validation: Dynamic loads - Crash Example: RCAR* bumper test Reference Part (Aluminum): Part weight = approx. 2100 g Emax = approx. 6.8 kj Intrusion depth = approx. 140 mm PulPress Part: Part weight = approx. 750 g Emax = approx. 6.8 kj Intrusion depth = approx. 125 mm * RCAR is a vehicle crash standard used in German insurance rating 15
Manufacturing Costs ( ) Case study: Significant cost reduction in making complex sandwich profiles Near zero production scrap 60% Improved cycle times A Simple. No intermediate steps Standard Process (e.g. RTM) PulPress Technology Excellent cost advantages, also for small series production Tremendous cost breakthrough (60%) for large series production 16
Summary Efficient processing High temperature PMI foam is the key element to facilitate stable processing No preforming or handling problems Reduced resin uptake Almost no waste of foam core, carbon fibers or resin High cost efficiency Cost reduction of up to 60% compared to today s standard processes, e.g. RTM Excellent performance & design freedom PMI foam as structural core is ideal for high performance, lightweight structures Superior performance validated under static & dynamic loads High quality Excellent bond between skin and foam core Narrow tolerances & reproducibility Functional integration Polymer or metal inserts can be easily integrated in process 17
Outlook PulPress transfers ultra-lightweight design to economic production. Potential applications in automotive: PulPress Shaping Future Mobility 18
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PulPress TM, Shaping Future Mobility. Cost / Weight indications 20