JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 52

USERS’ PLATFORM
Buses & Trucks
g…/… Low-cost structural thermoplastic composites for transport

Composite Solutions. Having previously developed a thermoset 28tonne trailer, EPL were able to quickly translate the properties of the TPC into a feasible design for a 13.5-m trailer (Figure 2) using a mixture of composites and mechanical design methodologies. Care was taken at every level to ensure that the trailer design was rugged and suitable for end users. The ancillaries used in the trailer are industry standard and not special lightweight products. The trailer has been designed for the widest use possible, i.e. if a tyre blows, or an axle or landing leg need replacing, any supplier in the current industry will be able to repair or replace the damaged part. All parts that require maintenance or replacement are easily at hand. The composite itself is designed to be easily repairable as it has been designed to the stage where sections can be cut from the trailer without affecting performance adversely. With the design in place, tooling was then designed and manufactured by project partner Basmiler in Portugal. Due to the size and relative simplicity of the composite shape, the tooling was manufactured from metal although

developed by EPL Composite Solutions, BAE Systems and EPL worked on the methodology to transfer lab-scale knowledge into the full-scale 13.5-m moulding. The trailer was designed around only three main mouldings and after some development (and the purchase of a 15-m oven), all three components were successfully manufactured via low-pressure moulding, the largest being the “hull” or base of the trailer which weighs over 1,000 kg and covers some 50 m² in area – the largest single, high-performance TPC moulding in the world. Investigation into joining techniques provided a simple and effective solution to create the monocoque trailer. Ancillaries, electrics and pneumatics were installed and the resulting trailer is currently undergoing a range of lifecycle tests on roads and test tracks in the UK. The trailer (Figure 3) has been measured and is currently producing weight savings of approximately 1,500 kg (generating over 700 litres of fuel savings per year) compared with the steel trailer that it has replaced. The trailer has the capacity to carry loads in excess of 30 tonnes and it only deflects by 8 mm when fully laden.

compression or injection moulding processes and possesses 80% of the properties of virgin stock material.

Aerodynamics
To enhance the environmental aspects of the design and to take advantage of

the composite’s shaping ability, a computational fluid dynamics (CFD) analysis was performed using racing car
Fig. 4: Aerodynamic profiling achieves huge benefits

Fig. 3: World’s first lightweight and aerodynamic thermoplastic composite trailer

technologies to reduce drag forces over the trailer and to improve its aerodynamic profile (Figure 4). The aerodynamic profile of the monocoque dramatically reduces drag and generates even greater fuel savings, giving a combined fuel reduction of approximately 15% – typically around 7,000 litres of diesel per year. The composite trailer carries additional cost over the conventional steel version but the payback is expected to be less than 2 years. EPL Composite Solutions Ltd. are seeking partners to develop and commercialise the composite trailer concept with a view to having a fleet on the road by 2013. More information: www.eplcompositesolutions.co.uk www.cleanmould.com info@eplcompositesolutions.co.uk

research also highlighted a range of feasible composite tooling options. Using the prepreg manufactured by Ahlstrom and the processing techniques

Recycling
IKV performed tests on the materials and developed techniques to recycle the trailer at the end of its useful life. The resulting recyclate can be used in

52

jec composites magazine / No59 August - September 2010


http://www.eplcompositesolutions.co.uk http://www.cleanmould.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010

Cover
Contents
NEWS WORLDWIDE
Goodrich Corporation acquires Crompton Technology Group
Reichhold expands manufacturing capacity in Turkey
LAP wins order from Airbus
Toho Tenax Europe to supply carbon fibre for Bombardier Cseries
Glass Fibre - A global competition for breakthrough composite applications
Agenda of events
Innovation - Phenolic prepreg products for interior applications
BUSINESS
Market survey: China Yuan Long FRP broadens its range of skills beyond pultrusion
Shanghai Tung Hsing Technology: steady growth through diversified markets
Niche Market Bio-based polymers: a revolutionnary change
Trends Kenaf, a fibre for the future: the Harusmas experience
Mechanical properties of naturalfibre-reinforced composites
FEATURE
Design - Wave impact resistance of racing yacht composites
Infusion - Regatta racing at the highest level
Adhesive - Flame-retardant adhesive for power packs in marine applications
Control - Validation of marine structures - Testing appraoches
Resin - New styrene-free resin: better for Catamaran Cruisers and the environment
VOC - Presatured wipes reduce VOC emissions
High performance - 48 days, 7 hours, 44 minutes around the world
USERS' PLATFORM
Composites in the world
Ying Yang table
The most luxurious golf car ever made
New carbon fibre band watch
Successful partners - A prefabricated FRP bridge for the oil and gas industry
Low-cost structural thermoplastic composites for transport
Making modular bus body shells from composite materials
Tougher fire-rated bus parts thanks to intumescent topcoat
KNOW-HOW
Bonding - Composite bonders - meeting the requirements of modern engineering
Manufacturing - ESTRIM - a fast-demoulding injection technology for epoxy composites
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 3
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 4
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 5
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Toho Tenax Europe to supply carbon fibre for Bombardier Cseries
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Glass Fibre - A global competition for breakthrough composite applications
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 10
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Innovation - Phenolic prepreg products for interior applications
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Market survey: China Yuan Long FRP broadens its range of skills beyond pultrusion
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Shanghai Tung Hsing Technology: steady growth through diversified markets
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 16
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Niche Market Bio-based polymers: a revolutionnary change
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 18
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 19
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Trends Kenaf, a fibre for the future: the Harusmas experience
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 22
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 23
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Mechanical properties of naturalfibre-reinforced composites
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 25
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 26
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Design - Wave impact resistance of racing yacht composites
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Infusion - Regatta racing at the highest level
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 31
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Adhesive - Flame-retardant adhesive for power packs in marine applications
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 34
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Control - Validation of marine structures - Testing appraoches
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 37
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Resin - New styrene-free resin: better for Catamaran Cruisers and the environment
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 39
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - VOC - Presatured wipes reduce VOC emissions
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 42
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - High performance - 48 days, 7 hours, 44 minutes around the world
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 44
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 45
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - New carbon fibre band watch
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Successful partners - A prefabricated FRP bridge for the oil and gas industry
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 48
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 49
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Low-cost structural thermoplastic composites for transport
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Making modular bus body shells from composite materials
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Tougher fire-rated bus parts thanks to intumescent topcoat
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 56
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 57
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Bonding - Composite bonders - meeting the requirements of modern engineering
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 60
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 61
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 62
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - Manufacturing - ESTRIM - a fast-demoulding injection technology for epoxy composites
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 64
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 65
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 66
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 67
JEC COMPOSITES MAGAZINE - Issue #59 - August/September 2010 - 68
https://www.nxtbook.fr/newpress/jeccomposites/jcm2007_135
https://www.nxtbook.fr/newpress/jeccomposites/jcm_2020_Q1_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_Special_Issue3
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_134
https://www.nxtbook.fr/newpress/jeccomposites/jcm2003_133
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
https://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
https://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
https://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
https://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
https://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
https://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
https://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
https://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
https://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
https://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
https://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
https://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
https://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
https://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
https://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
https://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
https://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
https://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
https://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
https://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
https://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
https://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
https://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
https://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
https://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
https://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
https://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
https://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
https://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
https://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
https://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
https://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
https://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
https://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
https://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
https://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
https://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
https://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
https://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
https://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
https://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
https://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
https://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
https://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
https://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
https://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
https://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
https://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
https://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
https://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
https://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
https://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
https://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
https://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
https://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
https://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
https://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
https://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
https://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
https://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
https://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
https://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
https://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
https://www.nxtbookmedia.com