New process of manufacture of composites that reduces the times of production
The composites are material of engineering of high value added, because of the advantages that present in front of another type of materials. His low weight, together with the high rigidity, has boosted his use during a lot of years for the manufacture of satellites, aeroplanes or ships. These materials have showed his cost in markets so sued as they are: automotive sector, infrastructures and sports material. However, the transition to many of these sectors demandantes is being very slow, mainly because of the low productivity of the processes of manufacture, which do not result profitable.
On the other hand, the industry of the transport every time has to fulfil environingingmental regulations more strict with the aim to increase the relation improves/weight. To be able to reach this aim, the compound materials present like key technology as long as they fulfil requirements eat: under weight, under cost and cadence of production required.
During the process of RTM (resin transfer moulding), one of the more employees for the manufacture of composites, employ gel-coat liquids that present important broadcasts of volatile organic compounds and long time of polymerisation. However, the utilisation of the gel-coat in shape of dust would delete these broadcasts and would have some times of polymerisation a lot lower, but at present only have formulated for the process of SMC (sheet moulding compound), not being adapted for the process of RTM.
The European project Ecogelcronos, in which it participates IK4-Cidetec, has like aim the design of a process of RTM of high innovative and ecological productivity that no only will improve the current times of cured of the composites, but also the quality of the pieces.
To attain this, the project will centre in the formulation and manufacture of a gel-coat in dust of cured fast for the manufacture of pieces of composite. This will reduce drastically the times of production and will minimise the broadcasts of estireno in the place of work. Besides, this type of coating will provide a series of improvements in terms of quality of the final piece.
Besides will develop moulds manufactured in composite in which the laminado of fibre of carbon will assume a double function, acting at the same time like structural reinforcement in the mould and like element heater, providing a surface of warming entirely homogénea. Incidentally, they will design and they will integrate all the materials and the necessary auxiliary systems to ensure an effective and effective use of the gel-coat in dust. Also they will develop preformas of fibre, what will allow to reach a high productivity in the manufacture of components of material composed for the sector of the automotive sector and general transport.
The reduction of the times of cured, together with the improvement in the quality of the pieces and the elder aprovechamiento of the prime matter (possibility of re-utilisation of the excess of gel-coat in dust applied, elder post-life, greater effective performance) derives in an increase of the productivity. But at the same time also in a reduction of the costs of production, that are at present the greater problem in the manufacture of the composites to world-wide level.
The project Ecogelcronos is focused to offer solutions to the industry to improve the hygiene and competitiveness of the process of RTM, entering diverse innovations of which expect the following results:
- Greater employment of materials advanced in products with behaviour improved without an increase in the cost.
- Reduction of 30% of the consumption of raw materials.
- Reduction of wastes and broadcasts in 80% during the application of the gel-coat and of 20% during the conformed of the fibre.
IK4-Cidetec has two main tasks in this project:
- Develop of a gel-coat electrically driver to be applied on the mould of RTM, allowing the application of the gel-coat in dust by means of electrodeposición.
- Develop of an adhesive bi-component hibrido epoxi/polyurethane for the union of materials disimilares plastic/composite and metal/composite, that allow to integrate the pieces developed by RTM with the rest of components of the vehicle.
In the project will employ two cases of study to show the advantages of the the new technologies developed. Besides, Ecogelcronos proposes a totally automated process to improve drastically the speed of current production.
Ecogelcronos It began in September of 2013 with a length of 3 years. The investigation that will drive to these results has received subvention of the 7º Program Mark of the European Union (FP7/2007-2013).
