JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 38

carbon fibre

composites in automotive different
from other market segments.

The best technology?
Obviously, the technology which
copes best and most cost efficiently
with the requirements for a given
automotive component is likely to win
the game. Prepreg has some disadvantages: 1) Due to rather bad drapability, complex 3D structures are difficult
to produce, while preform technologies based on fabrics or braiding, for
example, can cope much better with
this. 2) Standard prepreg processing
routes with autoclave, manual or even
automatized layup cannot reach the
required production rates economically. Thus a full process for automotive
prepreg processing is not established,
whereas RTM based on fabric preforms, for example, allows sufficient
production rates. 3) Cold storage and
transport might be necessary, which is
technically possible but adds cost.
On the other hand, prepregs also offer
some advantages: 1) Structures nearly
plain or only slightly curved in the
third dimension can be easily produced with standard cutting technology. The resulting preforms are stable
in shape and dimensions and easy
to handle compared to fabric-based
parts for example. 2) Prepreg layers
in multilayer preforms stick together
inherently, and no binder, sewing or
other auxiliary process is required. 3)
By putting an adhesive layer on top,
curing and joining with a metal part to
form a hybrid structure can be achieved in one main step like hot pressing.
In sum, prepreg-based CFRP production can be well suited for nearly plain
automotive components, large-scale
parts such as engine hoods or particularly small 2D complex stacks such as
reinforcing parts for hybrid components. In the best case, prepreg can be
the material of choice. However, this
requires the full-scale development of
automatized processing technology
coping with the above-mentioned
requirements in all process steps.

Fig. 2: SGL Benteler process for the production of reinforced B-pillars

Consequently, the key driver is the
development of these processes rather
than the development of prepreg
material itself. Of course, adaption of
prepregs to process might be required.
This is valid, for example, for resin
curing cycles of a few minutes. Here,
the available systems are sufficient,
although still shorter cycles would
result in further cost savings. Another
need is an excellent process reliability
and consistency. This translates back
into consistency of prepreg properties
or even into prepreg raw materials
such as high-consistency silicone-coated release liners on both a large and
small scale.

Prepreg-based process
An example for such a prepreg-based
process was implemented on a pilot
production scale for composite patchreinforced structural parts, i.e. B-pillars, by Benteler SGL (Figure 2). The
prepreg is processed into the hybrid
component in two main steps. UD
or fabric prepreg based on carbon or
glass fibre is used as raw material. In
the first step, the prepreg rolls and the
adhesive film are unwound and placed
directly onto each other to form a
multilayer. Stacks are cut directly out
of the multilayer and taken out by a
robot. In the second step, the stack is

Fig. 3: SGL Group's estimate for carbon fibre usage in various industry segments

38 jec composites magazine / No86 January - February 2014



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014

Cover
Edito
Point of view: volume production
Contents
Agenda of Events
COMPANY & BUSINESS
In Brief
Advanced materials
APPLICATIONS
Cargo
Marine
E-car
Motorcycle
MARKET
Glass fibre
Overview 2013
FEATURE PREPREG
Laminates
Paper
Equipment
Technology
Carbon fibre
Formulation
Process
Investment
Tool
RESEARCH & DEVELOPMENT
Additive manufacturing
Class A
TECHNOLOGY & INNOVATIONS
Cutting
PVC
Recycling
Design
Filament winding
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Cover
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 2
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Edito
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Point of view: volume production
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 5
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Contents
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 7
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 9
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - In Brief
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Advanced materials
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 12
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 13
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Cargo
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Marine
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 16
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - E-car
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Motorcycle
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 20
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 21
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 22
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 23
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Overview 2013
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Laminates
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 26
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 27
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 28
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Paper
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 30
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Equipment
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 32
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 33
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Technology
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 35
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 36
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Carbon fibre
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 38
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 39
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Formulation
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 41
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 42
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Process
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 44
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Investment
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Tool
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 47
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 48
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 50
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 51
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 52
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Class A
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 54
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Cutting
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 56
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - PVC
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 58
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Recycling
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 60
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Design
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 62
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 63
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Filament winding
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - Index
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - In the world
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 67
JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 68
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