schappe techniques tpfl

Schappe Techniques Proprietary and

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Plant :

Rue dAlsace F - 88 520 La Croix-aux- Mines

Tl: +33 (0)3 29 52 23 23

Fax: +33 (0)3 29 51 79 10

Administration & Sales Dpt :

Parc Ind. de la Plaine de lAin Alle des Erables

F 01150 Blyes Tl: +33 (0)4 74 46 31 00

Fax: +33 (0)4 74 34 79 35

Spinning company

Sales 2012: 13 M

- to France : 27 % of the sales

- to Europe : 46 % of the sales

- to ROW : 27 % of the sales

350 Tons of yarns/year

ISO 9001/2008 Certified

Schappe Techniques

138 employees


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Schappe Techniques position in the textile chain

Fibre producer

Weaver Knitter Braider

Intermediate product

manufacturers

(Composites for example)

Garment

Maker woven fabrics knitted fabrics braids

Garment makers, final product

Manufacturers (conveyor belts,

joint packings etc...)

fibres

spun yarns

Finished product manufacturers

(Automotive for example) Final market

finished

products

finished

products

intermediate products

finished products

Spinner

(Schappe Techniques)


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Schappe Techniques processes


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Schappe Techniques general processes

Stretch breaking Pin drafting Spinning Winding Twisting Control

Continuous filament

raw material

Yarn


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Specific processes to Stretch Broken fibers Standard spinning processes

The stretch breaking process


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Stretch breaking consists of transforming the continuous

filaments into a top of long fibers.

Originally, this technique allowed to remove the weak

points of the fibers and to improve their characteristics by

increasing their tenacity and spinability.

The stretch breaking process


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Fiber length diagram:

Typical lengths for carbon fibers:

Maximum length: 200-220 mm

Average length: 65-70 mm

Minimum length: 35-40 mm

Key Features of Stretch Broken Yarns

Versus continuous filaments:

Intimate blends for tailored properties (ie: composites) Cost competitive: Fine yarns made of heavy tows Larger metric count range Comfort and softness Higher bulk Lower tensile strength

Versus short staple yarns:

Higher tensile strength Higher abrasion resistance Higher Metric count limit : thinner yarns High flexibility for small productions (trials, sampling) Cleaner yarns (evenness, regularity)


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Sales segmentation Individual protection

Technical sewing threads

Fire blocking

Packing

Reinforcement

Antistatic

Glass industry

Composites


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Different types of yarns made by Schappe Techniques

Single: Yarn is twisted

Plyed yarn: Individual yarns are twisted and then plyed together

with opposite torsion

Plyed with steel: Steel(Inconel) yarn is inserted between the yarns

during the plying operation

Wrapped: Core is made of parallel or twisted filaments,

wrapping yarn is offering mechanical protection


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Schappe Techniques products for Composites

Thermoplastic prepregs: TPFL

Carbon/Carbon precursors

Thermoset reinforcements


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A drapable prepreg which can be consolidated in a

short time for the production of high performances parts.

The goal


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Detail of a TPFL yarn

Reinf. Fibre +

Matrix fibre

Matrix fibre

TPFL fabric

TPFL yarn


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The TPFL intimate blend (Before consolidation)

Polymer Fiber

(PA12, 50m) Reinforcement Fiber

(Carbon, 7 m)


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Air

Twintex - The Commingling Concept


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TPFL Yarn

Prepreg

Consolidated

Composite

Temperature

+ Pressure

The TPFL intimate blend

TPFL processing cycle (PEEK Temperatures)


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The TPFL portfolio


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Reinforcement fiber

The TPFL range

Intime blend

Matrix fiber

Sliver

Yarn

UD Sliver Preconsolidated UD UD Laminates Braids

Multiaxial

Pellets

UD Fabrics 2D

Fabrics

Preconsolidated

fabrics

Flakes


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TPFL combinations

Carbon

S2-Glass

Ceramics (Nextel, SiC)

Para-Aramide

Linen (Flax)

PA 12, PP

PPS

PEEK

Reinforcement

Fibers Matrix

LCP

PBT, PET

PEI


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What are the raw material selection limitations?

For Reinforcement Fibers Fiber sizing shall allow the fibers to slip during stretch breaking operations, but shall not be degraded during processing (temperature) and shall allow decent interface between matrix and fiber. Consequently: No E-Glass in our range

For Polymer Polymer shall be available as a fiber, continuous or long enough to be carded


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Typical properties of carbon fibers used by Schappe Techniques

Fiber Elongation Density Certified for

Aerospace

4000 Mpa 240 Gpa

580 ksi 34,8 Msi

4278 Mpa 228 Gpa

620 ksi 33,1 Msi

5570 Mpa 276 Gpa

808 ksi 40 Msi

Hexcel AS4 1,87% 1,79 gr/cm3 Yes

Hexcel IM7 1,90% 1,78 gr/cm3 Yes

Tensile Strength Tensile Modulus

Toho-Tenax STS40 >1,6% 1,76-1,82 gr/cm3 No


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Temperature

(C)

Polymer service temperatures

Tg

Tm

Ts

Polymers


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Polymer processing temperatures

Temperature

(C)

Tg

Tm

Tp


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New TPFL yarns and reinforcements proposed by Schappe


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Style Polymer Fiber

98644 PA12 S2 Glass

98645 PEEK S2 Glass

98705 PA12 Linen

98821 PEI Carbon

98799 PA12 Linen

98800 PA12 Linen

Style Polymer Warp Yarn Weft Yarn Construction Weaving

Pattern

Total Aerial

Weight

Fiber Aerial

Weight

Fiber

Weight

Fraction

Fiber

Volume

Fraction

Composite

Density

90153P PA12 3,8 x 3,8 2/2 Twill 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3

90154P PA12 3,8 x 3,8 4/4 Twill 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3

90155P PA12 3,8 x 3,8 Plain 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3

90173P PA12 98799 Nm 3,7 Linen/PA12 54/46 98800 Nm 7,4 Linen/PA12 54/46 3,8 x 3,8 2/2 Twill 351 Gr/m 5% 190 Gr/m 5% 54% 3% 40% 3% 1,31 Gr/cm3

90174P PA12 98799 Nm 3,7 Linen/PA12 54/46 98800 Nm 7,4 Linen/PA12 54/46 3,8 x 3,8 Plain 351 Gr/m 5% 190 Gr/m 5% 54% 3% 40% 3% 1,31 Gr/cm3

Style Polymer Warp Yarn Weft Yarn Construction Weaving

Pattern

Total Aerial

Weight

Fiber Aerial

Weight

Fiber

Weight

Fraction

Fiber

Volume

Fraction

Composite

Density

90156P PEEK 5 x 5 Plain 313 Gr/m 5% 188 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3

90157P PEEK 5 x 5 2/2 Twill 313 Gr/m 5% 188 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3

90160P PEEK 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3

90161P PEEK 40501 Nm 3,2 Carbon/PEEK 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 62% 3% 53% 3% 1,57 Gr/cm3

90163P PPS 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 54% 3% 1,58 Gr/cm3

90166P PPS 51804 Nm 3,2 Carbon/PPS 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 61% 3% 54% 3% 1,61 Gr/cm3

90178P PEI 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 52% 3% 1,53 Gr/cm3

90179P PEI 98821 Nm 3,2 Carbon/PEI 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 61% 3% 52% 3% 1,55 Gr/cm3

98705 Nm 2 Linen/PA12 64/36

New High Performances Fabrics

40501 Nm 3,2 Carbon/PEEK 60/40

New Yarns

Fiber Weight Fraction Fiber Volume Fraction Metric Count

40% 3% 7,4

72% 3% 52% 3% 2,4

67% 3%

98821 Nm 3,2 Carbon/PEI 60/40

60% 3% 52% 3% 3,2

54% 3% 40% 3% 3,7

54% 3%



51804 Nm 3,2 Carbon/PPS 60/40

New Natural Fibers Fabrics

98705 Nm 2 Linen/PA12 64/36

98705 Nm 2 Linen/PA12 64/36

52% 3% 2,2

64% 3% 57% 3% 2

Flax-PA12 applications


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Flax-PA12 applications


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Consolidation techniques

1. Most used

Cold stamping

Diaphragm forming

Bladder Inflation Moulding (BIM)

Compression Molding

Autoclave

2. Emerging processes (RocTool)

Inductive heating


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The stamping process

Pre-heating Preform placement

(Tp > Tm)

Stamping Demoulding


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The cold stamping process

Techniques that is widely used for consolidated thermoplastics, allowing fast processing

When using TPFL materials that are not consolidated, consolidation requires:

Pre-heating of the material to processing temperature, typically Tf + 30C

Time to allow the polymer to flow and wet-out the fiber

Cooling down the material until the T< Tg


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The stamping process

Sump, EMS Chemie - TPFL carbon/PA12


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The stamping process (Silicone tool)

Vido : TPFL_fabric.avi


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The diaphragm forming process

membrane

TPFL


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Silicone membrane

The diaphragm forming process

Gusset,EMS Chemie - TPFL carbon/PA12


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Key feature of TPFL materials Fibers are slipping during the process Yarns are elongating (Up to 20%) Absence of wrinkles in the edges

The bladder inflation moulding process

Use of TPFL braids Easy lay-up No joints, no overlap Possibility of evolutive sections, curved parts

TPFL


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The bladder inflation moulding process

Vido : TPFL_braid.avi

Real applications : Sporting goods with Carbon/PA12 TPFL braids. Typical cure

cycle: >5, 10 bars, T = Tf +30 C


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Compression molding and injection

Compression molding is already used with TPFL pellets

Development and characterization of TPFL flakes is ongoing. Goal is to make HP composites with injection


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Fast processing technique : Induction heating

3iTech tube video.mov

Use of induction heating system developed by

allows the use of silicone that are theoretically nor capable to withstand such processing temperatures. Reason is due to short thermal history of the silicone


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TPFL mechanical properties (UD)

Tensile Flexural

(MPa)

E (Gpa)

(MPa)

E (Gpa) Vf %

CF/PA12

CF/PBT

CF/PPS

CF/LCP

CF/Peek

-

1850

1400

1800

1080

123

85

120

-

98

1435

750

1650

1200

1010

100

92

101

105

107

53

53

53

53

53

Results obtained on UD at room temperature


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Please discard mechanical properties claimed for fabrics in TPFL brochure

The TPFL solution

Short cycle moulding

High Mechanical Properties

High drapability: Very suitable for complex shapes and hollow parts

Very low void content (






Confidential 46

Different types of yarns made by Schappe Techniques

Single: Yarn is twisted

Plyed yarn: Individual yarns are twisted and then plyed together

with opposite torsion

Plyed with steel: Steel(Inconel) yarn is inserted between the yarns

during the plying operation

Wrapped: Core is made of parallel or twisted filaments,

wrapping yarn is offering mechanical protection


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Multiaxial textures


UD Carbon

Carbon yarns


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Carbon/Carbon applications

Carbon Clutch pads

Rods and screws

Oven soles


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Thermoset reinforcement applications

Truck clutch pads

Industrial friction parts


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Carbon Sewing Threads


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Carbon thread 1K x 2

1. Developed by Toho-Tenax

2. Produced by Schappe Techniques

3. Nowadays marketed and produced by Schappe



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First flying application : B787 Main Landing Gear Brace (Messier-Dowty)



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Composite Door Demonstrator (Latcore)

Carbon thread 1K x 4

schappe techniques tpfl

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