The Winners of 2014 CCE-JEC Innovation Award——New Applications
原文：http://www.chinacompositesexpo.com/en/news.php?news_id=14461. Product Name: Continuous Fiber Reinforced Thermoplastic Pipe (RTP)
Source：China Composites Expo 2014-9-10
Exhibitor: JiangSu QIYI Technology Co., Ltd.
- Pipelines for Petrochemical industry, especially suitable for transporting high sulfur oil, gas, water, natural gas, etc.
- Pipelines for the chemical industry, for transmitting low temperature and corrosive media for acid and alkali salt manufacturing, fine chemical, chemical fertilizer, pesticide, pharmaceutical and other industries.
- Pipelines for Mining industry, for transmitting salt, water, etc.
Adopt the unique technology to make the high strength of the continuous fiber and thermoplastic resin "fully impregnated" with each other. Fiber content exceeding 60%it is shortnamed as "CFP; Continuous glass fiber reinforced polyethylene (PE) composite strip and it is the ideal RTP pipe winding reinforced material:
- Less than 1.5 g/cm3 density;
- The tensile strength is greater than 600 MPa;
- The fracture extension rate is less than 2%;
- In the temperature range - 40℃ ~ + 100℃,the strength of the still has good performance;
- Good impact resistance, corrosion resistance and salt fog resistance;
- Hot melt method can be used for bonding, repair;
1) Good anti-corrosive performance for both inside and outside of pipe shells, suitable for many corrosive media and environment. It has 20 years life time on the groud and 50 years life time underground.
2) 30-50% lighter than steel pipe with same diameter and under same working pressure.
3) Working temperature varies from -40℃ to 102℃. Good heat insulation performance. Under conditions of 30℃ temperature difference between in-and-out side of the pipe, temperature drop is less than 1℃ within 100 meters long pipe. Don't need a thermal compensation device.
2. Product Name: Carbon Fiber Bicycle Rims with Automatic Wrapping Technology
Exhibitor: Xiamen Hongji Weiye Industrial Co., Ltd.
This is a road bicycle rim. Place of production: Xiamen, China. For the carbon bicycle rims in the market, the majority of their tire beds are made manually, which can result in the low efficiency and unstable quality. In 2012, we developed the machine to realize the automatic production for carbon bicycle rims. Together with our high TG resin, the technology can greatly increase the physical performance and can make sure the rim endure the ultra high braking heat. So it’s fair to say that the technology solved the difficulty of the carbon fiber rim deformation caused by braking and loading.
This product use carbon fiber material which has high temperature resistance, corrosion resistance, friction resistance, fatigue resistance, etc. The rim had passed the test all aspects of the physical properties technology, such as the inflatable, positive pressure, lateral strength, the spokes tension, ravel-proof cover tyre, brake test, fatigue, and impact in our factory’ machine The brake side temperature can reach 220 degrees, the parallelism is 0.15 mm. Under the call of "energy conservation and environmental protection, green travel", carbon fiber as the environmental protection material, with the characteristics of low carbon, environmental protection, it can promote the begin development of the ecological environment aspects, and meet the demand of national planning.
At present, more and more cities build bicycle green way, cycling is chased again by people, this is a very important opportunity for carbon fiber bicycle development. Carbon fiber rim automatic wrapping technology is mostly use for racing bike, it was affirmation by customers at home and abroad from mass production, its various performance are passed by customers’ test, since its braking temperature could be 220 degree, it is suitable for cycling under every kind of environment and favored by customers, based on this, this product will be with broad prospects.
3. Product Name: LFT Engine Intake Manifold
Exhibitor: Great Wall Motor Co., Ltd. ; Tian Shui Rui Sen Te Auto Parts Co., Ltd.; China Automotive Engineering Research Institute Co., Ltd.
LFT engine intake manifold is mainly used to replace the PA+30% GF-30 of intake manifold. Based on the condition of the water pressure blasting and other performance, it can reduce weight by 15% to 17%. At the same time, the production process can also save energy and reduce emission. Currently, the new products’ water pressure blasting of intake manifold is around 0.63-0.70 MPa. Compared to the nylon products, it has a similar function but is at lower price. LFT granules produced by Tian Shui Rui Sen Te Auto Parts Company and LFT engine intake manifold can also be bulk supply after injection modeling and wielding.
We developed the material of automotive engine intake manifold, the long-fiber reinforced inside-kettle alloy polypropylene (LFT/PP) with independence intellectual property. This material improves machine performance and reduces product weight. It also maintains the weld strength of engine intake manifold above 0.63 MPa, which completely satisfies the technical requirement. Therefore, it is able to change the phenomenon that producing intake manifold has to be based on the (PA6+GF30) traditional short fiber reinforced nylon that imported from foreign countries.
Intake manifold acts a significant role in automobile engine. At the beginning, the selected material of intake manifold is cast iron. Then, it is changed to aluminum casting alloy that has 50% more weight loss compared to steel. Recently, the most popular material of intake manifold is short fiber reinforced thermoplastic composite materials (PA6+GF30) that composited by polyamide (PA) and glass fiber (GF). It is lighter than cast iron around 40%- 50%. PA6+GF30 material is an ideal source to make intake manifold. However, it has high model shrinkage, high rejection rate and high price of component; it is also easy to appear obvious shrinkage and deformation on the surface of work out part.
Following the Great Wall motor company, Tian Shui Rui Sen Te Auto company and China Automotive Engineering Research Institute company have teamed up to bring a LFT engine intake manifold. It avoided high cost and high rejection rate by using (PA6+GF30) material to produce intake manifold. Compared to material of PA6+GF30, LTD intake manifold has more weight lose 15%-17% with lower cost and high efficiency. The water pressure of intake manifold is measured around 0.63-0.70 MPa. The water pressure of nylon products is 0.69MPa.
The LFT intake manifolds have already passed the 1000 hours aging test and meet all requirements of intake manifolds. In the development of new products, we have analyzed the making process of LFT granules. The performance of granules is similar as products from foreign country. Moreover, we made a design by computer to simulate the production process for optimizing welds and structure of intake manifold. After a large number of welding experiments, we figured out the problem of weld strength and shortcomings of water pressure blasting. This project has declared an invention patents. It is a new material, new product and new making technology.
This product has been indicated by Great Wall motor company and China Automotive Engineering Research Institute Company. It meets all the requirement of automotive engine intake manifold. Particularly, the material of this product is cost-effective and excellent on comprehensive performance. The weld strength of intake manifold made by this material has reached more than 0.7MPa.
The national development and reform commission requested that average car fuel consumption of domestic passenger must be reduced by 15%. To achieve this goal, domestic car companies will make lightweight as the important direction of technology development. The intake manifold made by new material with lightweight technology has a smooth surface and low air intake resistance. Compared to the nylon products, the new material has a high efficiency and more than 17% weight loss. In addition, LFT can be reused that required by national automobile recycling policy.
Great Wall motor company, Tian Shui Rui Sen Te Auto Parts Company and China Automotive Engineering Research Institute Company jointly developed this product. After years of research and experiment, this product meet all standards of performance. Several car companies have been interested in purchasing this material since this product has a good-market currently.
According to expect of the china automotive engineering research institutes, the amount of domestic car sales will be around 25 to 32 million, of which 20 million car have intake manifold. In order to make the weight of intake manifold per car 2kg, the total weight of composite materials need to be above 40 thousand tons only for this part. Assuming the price of this material per ton is 20 thousands RMB, there are more than 800 million RMB of output value. If making intake manifold could create 1800 million RMB, the cost will decrease 200 million RMB compared to nylon products.
Long fiber reinforced thermoplastic composite materials have good performance and wide application, which has already received attention from industries and plastic composite research departments around the world. The LFT special material can also be used in other parts like the support of dial plate, front-end module, support of spare wheel and support of tail bumper.
4. Product Name: Carbon Fiber Electric Car
Exhibitor: Chery Automobile Co., Ltd.
Partner: Ningbo Institute of Materials Technology &Engineering, Chinese Academy of Sciences
Lightweight carbon fiber electric car is a strategic product to reduce energy and environmental burdens. This product is the first type of car with body made by carbon fiber composites and advanced manufacturing processes in China. It is also Chery's first plug-in hybrid car, which provides high efficient solutions for energy saving. The advanced materials and manufacturing processes can also be extended to manufacture other types of lightweight transports and applied in other fields. Production place: Chery automobile Co., Ltd., Wuhu City, Anhui Province;
Ningbo Institute of Materials Technology &Engineering, Chinese Academy of Sciences, Ningbo City, Zhejiang Province.
Carbon fiber reinforced composites have been widely used in aerospace, navigation, national defense, automotive, civil engineering and other fields due to their excellent properties such as light weight and high strength in recent years. This product is a plug-in hybrid electric vehicle with carbon fiber body made by advanced manufacturing processes. The innovation points include the followings:
1) Lightweight technology: the lightweight carbon fiber body is 218Kg with reduced weight 200Kg compared to the original metal body; the vehicle weight is 1340kg.
2) Energy saving and environmental protection: the vehicle weight reduces by 15% and 0.5 L fuel per 100 km can be saved.
3) Safe and reliable: energy absorption average unit weight is about 2.5 times higher than steel, which obviously improves impact resistance.
4) Strong controllability: 48% body-weight reduction brings excellent driving performance.
5) Cool fashion style: black cool fashion style brings a strong visual experience.
6) PHEV: advanced hybrid power system for front-engine front-wheel-drive vehicle makes driving smooth, fast and long.
The carbon fiber body weight is 218kg, with a weight reduction of 48% compared to the metal body (418 kg). The vehicle weight is 1340kg, with a weight reduction of 245kg to the traditional one. This product uses plug-in hybrid power. Lightweight carbon fiber technology and plug-in hybrid power can reduce pollution and emission effectively, which promotes environmental protection.
Energy saving analysis for lightweight body:
Vehicle weight (Kg)
Fuel consumption (L/100Km)
0.5L fuel per 100 km can be saved. RMB 750 can be saved for 20,000 km per year.
With the challenges of safety, energy saving and environmental protection in the global automotive industry, electric car technology is a strategic part dramatically reducing the energy and environmental burdens. Carbon fiber composites open up great potential in electric cars for weight reduction, which have been growing steadily, especially in automotive and aerospace applications. Compared to steel, it can reduce 50% weight with the same stiffness and strength properties and decrease assembling cost. Its excellent properties such as energy absorption, fatigue and corrosion resistance can obviously improve impact resistance and life service. The flexible designability and cool carbon fiber appearance bring a strong visual experience. It shows great potential in industrial applications and will further promote the development of new markets for composite.
5. Product Name: The Inside Grid Stiffened Structure
Exhibitor: Harbin FRP Institute
The main load-bearing structure is applied to some satellite system. The main camera, hood, trusses and most equipment racks on the satellite are installed thereon.
The inside grid stiffened structure is a hollow enclosed structure with grid stiffeners inside, Lattices 3mm thick, the upper and the lower are separately 4mm, 6mm thick. Internal embedded parts and composite materials are integrally processed. One of the technical difficulties of primary backplane is a closed primary structure, difficult to molding. Combining the module mandrel with outer metal mould simplifies the molding process of composite components. The other difficulty is the complex structure that the embedded parts and composite materials are integrated process, due to the different thermal expansion coefficients of metals and composite materials. To solve this problem, the research team attached a film layer to the interface between the metal and the composites. The film is an elastic materials that can offset the force of the metal thermal expansion, and then make metal and composite material effectively bonded together, avoiding the delamination.
It is not reported domestically after information retrieval about materials and manufacturing of the mould, the integrated process of composite enclosed structure with inner grid stiffeners. The project fills the gap in this field.
6. Product Name: Super Low Wind Speed and Ultra Slender Blade: Sinoma51.9 - 1.8MW
Exhibitor: Sinomatech Wind Power Blade Co., Ltd.
Partner:Envision Energy Co., Ltd.
Environment and energy issues is the driving force for the green energy development. As the core component of the turbine, Sinoma51.9-1.8MW blade is designed for the low wind area, which represents 68% of china’s wind field, especially for where the average wind speed exceeding no more than 5.5m/s. Production place: Beijing, China.
Comparing to similar product in China, the innovative points include:
1) Applying bending-torsion coupling rto achieve an ultra-slender blade design. The design will realize the lightweight of slender blades, decrease the load and make the blade a high efficiency comparing with the other 50.4m blade, its APE is increased by 5% in exchange for 5%increase of energy output. Also comparing with similar blade, the blade load is 20% lower.
2）Applying advanced materials to the root of blade, relieving the fatigue and saving cost. The advance materials helps to optimize load distribution, avoiding cost increase caused by adding more bolts and bearing replacement. Comparing with the similar blade longer than 50m, the root Bolt Center Diameter is 17% smaller and the weight is more than 10% lighter.
3）Introducing a new design concept for the spar boom (with a transitional width), ensuring the tip clearance of the slender blade and solving the assembling difficulties caused by limited space.
4）Symmetric root design is to reduce the bending effect of root which help to resolve the fatigue issue, making the root bolt and FRP both having higher resistance for fatigue load.
5）Current global lightest blade when the blade is longer than 50m.
Technical indicator of the blade:
- Technology characters is as follows:
- Nominal power：1.8MW
- Blade length：51.9m
- Max chord：2.7m
- Swept area：8826m2
- Wind class：IVA
- Temperature range：-30°C ~ +45°C
- Max Cp：0.475
- Cut-in wind speed：3m/s
- Cut-out wind speed：20m/s
- Nominal wind speed：9.5m/s
- Nominal rotation speed：15.6
- Tip speed ratio：11.0
- Annual mean wind speed：5.5m/s
March 15th, 2014, Sinoma finished the Design Assessment and have got the certification from Germany certificating body DEWI-OCC., finishing the static test on January 25th, and will finish the full scale fatigue test at the end of June, 2o14. At the first quarter, this blade has been running on the turbine in JiandShu province, the calculated energy output hours is 2100h. Now market need at least 800MW. Also this blade opens a time for China’s ultra-low speed wind zone blade.