JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019 - 30

FEATURE carbon
Focus on innovation
-- Extensible and transformable
-- Equivalent modulus and 80%
strength of UD prepreg
-- One-shot moulding and quick
cure
-- Multiple rib formation from
flat laminate in compression
moulding
-- Excellent drapability similar
to woven fabric used in preforming processes

Fig. 2: Application to
Crown for Golf Club
"Tour World 747"

Fig. 3: Application to
"MotoGP" Machine

customers in the sports and leisure field
and also by companies in the automotive,
aircraft and electrical goods industries. The
product was officially launched in April
2018 in Japan.
ET40 has the potential to expand the application of composite materials to products
requiring high mechanical properties which
could not previously be moulded with UD
prepreg. The extensible and transformable
nature of ET40 will also allow a greater design freedom. Potential applications include
sports and leisure but are not limited to a
design focused on aesthetics as the product
can provide high mechanical properties
compatible with the production of structural
parts. Aircraft and automotive structural
applications are expected in the near future.
The simplified "one-shot" manufacturing
process of pre-stuck laminate enables a faster
and more efficient production of parts that is

30

compatible with mass production. ET40 can
also be used with quick-cure resin systems
and contribute to reducing moulding cycle
times. There are therefore numerous benefits
for manufacturers who choose to adopt it.
Sport applications
Since ET40 has the potential to create
structural parts with complex shapes, its
use will expand the potential applications
of composite materials. Manufacturers will
have a greater freedom in the design of
their products as it provides high mechanical properties and excellent formability. By
using ET40, manufacturers will be able to
improve their productivity rates and create
lighter products, which combined, will contribute to energy savings. The application of
ET40 to transportation applications, such
as automobile and aircraft, will also create
lighter vehicles that will have a positive

	 jec composites magazine / N°129 July - August 2019

impact on the goal to reduce global CO2
emissions.
Recently, many golf club makers started
choosing carbon composites for driver
heads due to their lightweight properties
and increased design freedom. Honma Golf
newly designed and manufactured a crown
with multiple ribs using Torayca® Prepreg
ET40. While a conventional carbon crown
is 0.55-0.73mm thick and weighs 10-13g,
the use of ET40 drastically reduces the
thickness and weight to around 0.4mm and
7g, respectively, making it the world's thinnest and lightest carbon crown (at the time
of August 2018, investigated by Honma
Golf). (fig.2)
The internal rib structure provides the
strength and optimum deflection required
to play golf at the highest level.
In MotoGP, which is the premium category
for motorbike racing, Suzuki replaced the
conventional woven prepreg used in the
manufacturing of cowls for bike bodies with
Torayca® Prepreg ET40. (fig.3)
The material was chosen for its excellent
drapability, similar to woven prepreg, and
for the greater freedom of material choice
in terms of fibre areal weight, resin content
and choice of resin, modulus, and its
superior surface flatness. By applying ET40
with minimal resin content and a simplified
painting process (as a result of its smooth
surface), a drastic weight reduction of approximately 10% was achieved. In addition,
ET40 was also used to reinforce the bike's
aluminium frame to create a thinner and
lighter frame while retaining the required
stiffness.
More information:
www.torayca.com/en
http://www.torayca.com/en
JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #129 - July/August 2019
