As the composites market pursues automated processes for high-rate production, Porcher Industries’ Dry Fibre offers a way of processing materials out-of-autoclave (OOA). It is a versatile range of carbon fibre functionalised with a binder interface. Optimised for AFP-made preforms for thermoset resin infusion or injection, Dry Fibre provides similar component properties to conventional prepreg stacking, enabling the high speed production of complex shaped parts. The technology uses a cost-effective one-step-process to impregnate the fibre. As a result, Dry Fibre can be produced in flat calibrated width for AFP or rounder non-calibrated formats for winding, with a variety of different fibre aerial weights, binder chemistries and binder rates available on request.
Other features include: 100% continuous fibre with no splices that boasts excellent steering in high curvature AFP lay-ups; no need for paper or film interleaves meaning less waste and risk of fuzzing; good epoxy resin compatibility and a long shelf life.
Sustainable Greenlite fabrics
Porcher Sports will showcase its GREENLITE range of fabrics. Previously recognised with a JEC Innovation Award, GREENLITE fabrics use low density cellulose fibres to produce a range of reinforcements that are biodegradable, highly compatible with bio-resins and suitable for large volume manufacturing of bio-based composite sporting goods such as skis, snowboards, rackets and bike frames. As well as their contribution to sustainability, GREENLITE composites exhibit exceptional vibration dampening characteristics, improving comfort and reducing fatigue in all performance sport applications.
Thermoplastics for automotive
Porcher will be showing its range of technical textile composite solutions for the automotive sector, from woven fabrics, to PiPreg thermoplastic prepreg materials and pre-consolidated cured laminates. It will also showcase an enhanced thermoplastic portfolio with the newly introduced PolyPreg, a co-mingled glass and polypropylene fabric. These solutions are available for the most demanding applications in vehicle manufacturing.
Reinforcements and fabrics for construction
The Porcher Industries building team will showcase its range of glass, carbon and glass/carbon hybrids for the construction market. These high performance reinforcements are used in applications such as the strengthening and repair of concrete columns, beams and floors.
In addition, Porcher has now added a non-combustible line of FLAMLINE glass fabrics to its range. These are used when the highest levels of fire, smoke and toxicity protection are required in textile applications such as acoustical insulation panels, stage curtains, and upholstery interliners for furniture.
Porcher will also showcase textile solutions for thermal, acoustical, and solar protection across the construction market.
High performance carbon/PEEK
Thermoplastic composite materials offer the possible the replacement of metallic parts, offering excellent chemical resistance without any additional surface treatment or coating. Porcher Industries Industrial will showcase long lasting high-performance carbon/PEEK parts used in specialist pumps in the chemical production industry.
Arches Box TP Project
The Arches Box TP research project developed by STELIA Aerospace and Porcher Industries will be a key focus during the show. Porcher will present thermoplastic strengthening frame components that were developed for the Arches demonstrator on the Porcher booth, whilst STELIA Aerospace will display the full-scale thermoplastic fuselage demonstrator in the Planets section at the show.
Having been nominated together for a JEC Innovation Award (along with partners SINTEX NP, Compose Tool, CETIM, Aviacomp and Institut de Soudure), Porcher and STELIA will co-present a paper titled ‘Design to Cost Concept for Thermoplastic Laminates’ on Wednesday 7 March. Presented by Pierre-Yves Gandon, Aerospace Technical Support, Porcher Industries and Loic Le Lay, Composite Manufacturing, STELIA Aerospace, the paper will highlight two key innovations that were used for the strengthening frames of the Arches Box aircraft fuselage. The presentation will detail how two new thermoplastic semi-finished products were successfully developed: a woven 3k carbon/PEKK laminate and woven 12k carbon/PEKK laminate. Through extensive R&D by both companies, several parameters including fibres, weaving patterns, surface modifications and processes, were explored to optimise the impregnation, consolidation and processability of these organosheets.
Porcher has developed a new surface modification for the carbon fibre itself as well as a specific low crimp weaving technology for the heavier 12k tow. The combination of these two processing methods resulted in the more cost effective 12K carbon/PEKK laminates exhibiting the same mechanical performance level as the standard 3K carbon/PEKK laminates.
The influence of these innovations and parameters on the mechanical, thermal and ageing properties of laminates will also be presented, with particular focus on these thermoplastic semi-finished products’ excellent performance/weight ratio and performance/cost ratio for structural parts.
Visit Porcher Industries in Hall 6, Stand M28 at JEC World 2018.