There is a need for reproducibility, quality and efficiency at a reasonable cost – challenges that this company, with its many years of experience in non-crimped fabrics (NCFs) made from glass and carbon fibres, has been tackling.
More specifically, Karl Mayer Technische Textilien has extended its spreading technology to include suitable heating and impregnating modules. The result is a machine system that is setting the trend. This new development delivers a continuous mode of operating a high production speed and large tape widths. It represents Karl Mayer Technische Textilien’s latest step along the way to being a systems supplier for dry and impregnated NCFs.
High product quality
This new system combines spreading and impregnating in an efficient processing sequence on a single line and is based on tried-and-tested technologies. The spreading module is based on Karl Mayer Technische Textilien’s spreading technology. The components have been completely revised and produce a thin fibre bed that guarantees short flow paths during the subsequent impregnation process. This means that the rovings are optimally impregnated with the matrix material. Thanks to Karl Mayer Technische Textilien’s extensive knowledge and expertise, the spreading and impregnating sequences are linked by an optimum interface. This seamless transition ensures that the high spread quality of the fibre band supplied is not reduced by impregnation.
The matrix impregnation process is based on the film stacking process, and the materials used are thermoplastic films and webs. The matrix can be dosed exactly, and the fibre volume content can be set accurately. The matrix and fibres are combined with each other by heat supplied from multi-level IR heating zones. Calender modules apply the necessary pressure to the tape. This is followed by cooling, edge cutting and rolling-up. Thermoplastic, fibre-reinforced tapes are produced, in which the fibres in the continuous fibre reinforcement are in exact alignment. They are ideal for use in highly stressed, fibre-reinforced, lightweight structures.
The new line for producing high-end, thermoplastic UD tapes has a maximum working width of 800 mm and operates at a maximum rate of 10 m/min. Glass fibres up to a roving count of 2,400 tex can be processed. The materials that can be used and the technical configuration will depend on the requirements of each individual sector. This results in a good cost:benefit ratio. The acquisition costs can also be reduced considerably by using Teflon-coated conveyor belts instead of the usual steel belts. The investment costs for Karl Mayer Technische Textilien’s new line are considerably lower than for similar systems available on the market. Quality control systems are also available as an option to meet sector-specific quality requirements, such as those made by car manufacturers.
The modular construction enables the line to be adapted to meet the requirements of customers in other sectors as well. The design features that can be varied include the speed of the line, the construction of the textile reinforcing structure, and the use of different matrices and fibres.
As well as the overall technical design of the line, well-thought-out features guarantee an optimum cost:benefit ratio. For example, a new turret winder enables the line to operate continuously. This is especially important for avoiding quality variations as a result of changes in the pressure and temperature conditions caused by stoppages.
Companies: Karl Mayer