JEC COMPOSITES MAGAZINE - Issue #91 - August/September 2014 - 26

resin

Fig. 2: In addition to Henkel, the KraussMaffei
partner network includes Dieffenbacher, Zoltek,
Chomarat, Rühl Puromer, Alpex, Mühlmeier and
Roding Automobile GmbH

combine lightness in weight with enormous
strength, thus also offering outstanding characteristics in terms of safety and crash behaviour. Good mechanical properties, such as
rigidity, in the resin system employed are
thus essential, particularly when it comes to
absorbing the huge forces encountered in
motor sports.

Meeting automotive
industry requirements
Until now, there have been certain limitations in the use of lightweight components
as they are restricted in the degree to which
they can meet the requirements of the
automotive industry with respect to cycle
times and level of automation. In particular,
composites have been very rarely used for
the external components of vehicles as the
requisite post-treatment of the surface for
subsequent painting has been too costly and
time-consuming, based as it is on manual
processes. KraussMaffei - a leading manufacturer of machines for the production and
processing of plastics - together with a partner network to which Henkel also belongs

as a specialist for matrix resins, has now
succeeded in producing, in a fully automated
process, composite components that exhibit
a surface quality suitable for immediate
painting. This has become possible thanks
to the development of Loctite MAX 3. This
new, three-component polyurethane-based
matrix resin system from Henkel contains
not only the resin and hardener but also a
high-performance release agent aligned to a
self-releasing polyurethane lacquer manufactured by Rühl Puromer GmbH.

Increased temperature resistance
directly after demoulding
The polyurethane-based matrix resin
technology is characterized by significantly
faster curing compared to the epoxy resins
commonly used for the RTM (resin transfer
moulding) process. Due to its low viscosity,
the resin penetrates the fibre material more
easily and with less alignment disruption, giving rise to shorter injection times and thus
short cycle times in series production. The
outstanding toughness of the new matrix
resin further facilitates achievement of an
optimized component structure. Henkel has
also improved the temperature resistance
of the PUR resin, bringing Loctite MAX 3
up to a level comparable with that of epoxy
resins in relation to this particular property.
This high temperature resistance means
that the fibre-reinforced composites can be
demoulded more quickly. With the internal
release agent ensuring easy detachment of
the component from its mould, the resulting
surface is of sufficiently high quality to allow
immediate painting and bonding. While
enabling manufacture of external and visible
components with an outstanding surface
quality, this also accelerates the production

Fig. 3: Its low weight (950 kilograms) means that the Roding Roadster offers significant advantages...

26 jec composites magazine / No91 August - September 2014

Fig. 4: ... in terms of driving dynamics, vehicle
wear and efficiency (photo: Roding Automobile
GmbH)

process, facilitating increased automation
and thus mass production.

Flexible inclusion within
an integrated concept
For the automotive industry particularly,
integration within an overall package is
essential for this technology to be regarded
as an application solution. Consequently,
Henkel offers individually formulated
adhesives under the Teroson brand designed
to ensure the reliable process integration of
the different component materials within
the framework of advanced multimaterial
concepts. The various elements must be
ideally coordinated if the adhesives are to
perform to their full potential.
With Loctite MAX 3, Henkel offers a matrix
resin system that further increases the feasibility and attractiveness of manufacturing
automotive parts from composite materials.
The company has optimized the properties
of the resin so that both painted coatings
and adhesives can be applied to the resulting
composite surface without the need for any
pretreatment. Complemented by the adhesives portfolio from Henkel, this gives rise
to a complete system solution enabling the
manufacture and integration of composites
in automobiles. n
More information: www.henkel.com

http://www.henkel.com

JEC COMPOSITES MAGAZINE - Issue #91 - August/September 2014

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #91 - August/September 2014