JEC COMPOSITES MAGAZINE - Issue #86 - January/February 2014 - 64

filament winding
of delivering 10-110 g.min-1 of resin
and hardener, and handling liquids with
viscosities of 20-10,000 mPa.s. A feedback
control system between the rotating mandrel and the resin dispensing unit is used to
control the relative throughput of the resin
and hardener. The resin dispensing unit is
manufactured by CTM Ltd., which is also
part of the UK consortium. A schematic
illustration of the filament winding concept
is presented in Figure 1.
The other important component in this
clean wet-filament winding technology
is the fibre bundle spreading station; the
controlled spreading out of the fibres prior
to resin impregnation increases the width
of the tow while reducing its nominal
thickness. This has the positive effect of
efficiently increasing the impregnation
of the mixed resin system into the fibres
prior to being wound onto the mandrel. A
schematic diagram of the complete process
is shown in Figure 2.

Productivity and cost benefits
For manufacturers, there are several major
productivity advantages over a conventional wet resin bath in using this new
filament winding technology with a metered static mixer and resin impregnation
head. The custom-built metering system
automatically draws the resin and hardener in the required stoichiometric ratio as
needed from the individual bulk reservoirs.
This eliminates the need for any pre-weighing and manual mixing of the resin and

hardener, with the subsequent benefits
of eliminating disposable consumables,
such as containers, stirrers and paper and,
more importantly, avoiding the problem
of air entrapment, a real issue with manual
mixing. The other key productivity and
cost saving gain of this new automated system is that the process can be truly 'continuous' and not limited by the mixed resin
volumetric capacity of a wet bath, which
must be replenished manually; the resin
and hardener reservoirs can be replenished
during production with no interruption to
the line.

A fully operational prototype of the new clean
wet-filament winding technology developed by The
University of Birmingham's School of Metallurgy
and Materials and a UK consortium

Less cleaning and waste
This significantly cleaner wet-filament
winding process, which has achieved up
to an 80% reduction in cleaning solvent
consumption along with an equivalent
reduction of mixed resin waste, is due to
two key factors. Firstly, with no resin bath,
the need to thoroughly clean the equipment at the end of each production run is
eliminated. Depending on the dimensions
of the resin bath, the cleaning operation
consumes several litres of solvent plus the
associated consumables, which all have
to be disposed of along with the waste
mixed resin; the need to take exotherming
precautions with waste mixed resin is also
eliminated. Secondly, the unit has been
designed such that final roller of the resin
applicator is positioned above the mandrel.
Therefore, unlike a conventional wet-filament winding process, with this configu-

Filament-wound pipes made with the new technology prototype unit. A variety of thermosets, including faster curing resins, have been successfully
trialled with this new filament winding technology,
which can be retrofitted to existing filament winding
systems

ration the problem of resin dripping from
the impregnated tows on to the floor is
eliminated.

UK consortium members
The UK consortium members of this
collaborative project are the University of
Birmingham, Mouldlife Ltd., Pultrex Ltd.,
CTM Ltd., Halyard Marine Ltd., Luxfer
Gas Cylinders Ltd., PPG Industries Ltd.,
and Bruker Ltd. The project started in 2010
with backing from the UK's innovation
agency, The Technology Strategy Board,
a government-funded body which helps
companies develop and commercialise new
manufacturing innovations. n
Fig. 2: Schematic illustration of the clean filament winding process. The key components are coded as follows:
(A) Fibre creels. (B) Fibre guide. (C) Tensionning system. (D) Guide pins. (G) Resin-impregnated fibre bundles.
(H) Traversing carriage with a platform/adaptor to house the impregnator (viii). (I) «Collector» roller or D-ring;
(J) Rotating mandrel. (K) feedback control unit. Refer to Fig.1 for a description of (i-viii).

64 jec composites magazine / No86 January - February 2014

More information:
www.mouldlife.co.uk
www.pultrex.com


http://www.mouldlife.co.uk http://www.pultrex.com

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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