EUREKA PROJECT > 2534 THERMOPOLE
- SUMMARY
- OUTLINE
- PARTICIPANTS
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UNITED KINGDOM
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GERMANY
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DENMARK
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DENMARK
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CANADA
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RESEARCH, DEVELOPMENT AND DEMONSTRATION OF NOVEL PROCESSING TECHNIQUES FOR STRUCTURAL THERMOPLASTIC COMPOSITE POLES
NOVEL METHODOLOGIES FOR PREFORMING AND MANUFACTURING THERMO- PLASTIC COMPOSITE COLUMNS WILL BE DEVELOPED. CASE STUDY STRUCTURES WILL BE DESIGNED TO COMPLY WITH RECENT EUROPEAN PASSIVE SAFETY STANDARDS AND FABRICATED TO PROVE THE PROCESS
Status > FINISHED - 18-Nov-2003 Technological Area Market Area Start Date > 05-Dec-2000 Duration > 33 Months Participating countries > UNITED KINGDOM, DENMARK, GERMANY, CANADA | Main contactEURO PROJECTS (LTTC) LTD.
MR. GERARD S. BOYCE > DIRECTOR Organisation type > SME |
Project Description
There is a legislative requirement to reduce styrene emissions during the manufacture of polymer composite materials. There is a requirement for roadside equipment to be categorised in accordance with its passive safety performance. To remain competitive there is pressure to reduce manufacturing costs and materials usage and improve product performance. Specific processing limitations include the inability to produce tapered or stepped column forms continuously or at high speed and the fabrication of tapered wall thickness. More versatile thermoplastic composite materials have recently been developed that are potentially able to overcome these limitations whilst retaining many of the performance advantages of conventional thermoset systems. The successful application of these new materials is envisaged to result in a step change in manufacturing technology for tubular forms. The overall objective of this project is to research, develop and demonstrate a novel high speed processing methodology for the manufacture of tubular thermoplastic composite components. The specific objectives are: * To develop automated high speed fibre placement techniques and associated software which will enable continuous thermoplastic yarns to be positioned on tapered mandrels. * To develop techniques to enable longitudinal, UD fibre placement whilst decreasing wall thickness towards the tapered end of a tube. * To research and develop the application of woven tapes and fabrics to increase production speeds. * To develop a technique for creating 3D preforms to complex moulded shapes. * To research and develop techniques to produce a high gloss, pigmented and UV-resistant surface finish that eliminates fibre and ply overlap print through. * To research and develop a processing technique that enables the thermoplastic composite to be consolidated and de-moulded within a 20 minute cycle, whilst retaining a high level of material properties. * To investigate and demonstrate techniques for joining attachments to tubular columns using bonding or welding. * To design, develop and prototype 3 case study components, namely: - 8 metre tapered flag pole, - 8 metre stepped lighting column, and - 10 metre utility pole. * To confirm the design and processing methodology by achieving compliance with EN40 and EN 12767 and other appropriate national standards for the case study components. * To disseminate the technology effectively through technical publications and demonstrations of the performance of the case study components. The basic research elements include the development of the materials, yarns, tapes and fabrics appropriate for two preforming options to be addressed. Necessary equipment and software will be developed and consideration will be given to design aspects such as surface finish and jointing sections. Processing trials and testing of elements will enable key processing parameters to be identified and processing windows to be established. An applied research stage will focus on applying the technology to 3 case study components, a utility pole, a lighting column and a flagpole. These will pose different technical challenges in terms of design requirement, materials configuration and aesthetics and will be carried out in CANADA, the UK and DENMARK respectively. Full-scale prototypes of each case study will be produced and subjected to static and dynamic testing in accordance with EU standards to confirm the design methodology and process performance. Several design and process iterations will be undertaken whilst scaling up component size. Keywords: composite, manufacturing, columns.
Technological Development Envisaged
The main technology developments in the project are as follows: * Specialist winding equipment and associated software to mass produce fibre preforms that taper in length and varying thickness. * Specialist 'shell' preforms for building up stepped components made using diaphragm forming techniques. * A rapid consolidation process for heating, pressurising and cooling thermoplastic preformed components via mould transfer. * The application of specialist films to assist with moulding performance, product aesthetics and UV resistance. * New jointing techniques for the structural attachment of brackets and fixings. The main thrust of these developments is to dramatically decrease cycle times, reduce materials consumption and increase the quality and performance of the resulting products. Note under relationship to other EU Programmes: Project No. BRPR 97 0379 "Developed composite safety fences and lighting columns based on thermosetting composite materials" and Project No. BRPR CT 96 0228 "Developed thermoplastic processing technology for boat hulls, insulated truck panels and flagpoles". The current project will build on this expertise.
Main contactEURO PROJECTS (LTTC) LTD.
MR. GERARD S. BOYCE > DIRECTOR Organisation type > SME |
Contribution to project
* Task 12 - Project Management Project technical and financial management. Co-ordination of research activities and preparation of progress reports.
Expertise
Expertise: EPL have: * specialised in the development and processing of thermo- plastic composite materials and processes for over 8 years. * filed 5 patents relating to processing of thermo- composites and been granted a UK patent on the low pressure moulding of thermoplastic composite structures. * specialised in the design of FRP utility poles and lighting columns for 6 years. * formed SAFECOMP LIGHTING SYSTEMS LTD. in 1996, through which sales of composite lighting columns enter the market. * extensive experience in managing international collaborative R & D projects. Contribution: * Task 3 - Preform Development Processing expertise and the development of a diaphragm forming technique to consolidate shell preforms which can accommodate changes in section. Determination of optimum fabric form for shell production. * Task 4 - Processing Trials Research into processing options for achieving rapid heating and cooling of components. Focusing on the assembly of shell preforms onto the mandrel and techniques to produce a tubular sections with a step profile. Assistance with development of processing technique for wound preforms. Thermodynamic analysis of heat flow during processing. Assessment of coating systems for UV stability and aesthetic finishes. * Task 5 - Element Testing Analysis of test results for mechanical performance of coupons and sections of pole. Determination of design data and interpretation of processing efficiency. * Task 6 - Case Study Specification of case study lighting column, initial design of critical sections for processing trials and final design of component in accordance with EN 40 and EN 12767. Assistance with detailed design of utility pole and flag pole case studies. * Task 7 - Prototype Processing Processing of lighting column case study components and process optimization. * Task 8 - Refinement of Design Design modifications as required from testing results. * Task 9 - Full-Scale Testing Calculation of testing regimes in accordance with EN 40 and supervision of test procedures. Establishment of test plan and testing in accordance with EN 12767. * Task 10 - Technology Assessment Detailed technical and economic assessment of the project with respect to the lighting column case study. * Task 11 - Dissemination Assistance and co-ordination of dissemination programme. Writing and publication of technical papers. Development and hosting of Web site for project.
Main contactSAERTEX WAGENER GMBH & CO. KG
MR. BRUNO LAMMERS > DIRECTOR Organisation type > SME |
Contribution to project
* Task 1 - Materials Development Development/supply of woven thermoplastic tapes and fabric. * Task 2 - Equipment Development Assistance with fabric handling and feed design.
Expertise
Expertise: one of Europe's leading producers of stitched fabrics in glass, carbon, aramid and thermoplastic composite. SAERTEX employ the latest fabric and preform manufacturing equipment with the ability to customize fabrics for special purpose requirements. Contribution: * Task 3 - Preform Development Supply of materials for the preforms. Advice on fabric handling. * Task 7 - Prototype Processing Provision of materials for production of preforms. * Task 10 - Technology Assessment Contribution to the economic and market assessment for the new technology. * Task 11 - Dissemination Assistance with dissemination of the project results.
Main contactACCUSOFT SERVICES CORPORATION
MR. MITCH BERLINIC > DIRECTOR Organisation type > SME |
Contribution to project
* Task 2 - Equipment Development Software development to filament winding equipment for the production of tapered and varying thickness preforms.
Expertise
Expertise: they specialise in automated manufacturing systems and software particularly for filament winding. Contribution: * Task 3 - Preform Development Assistance with programming winding sequences for the production of preforms. * Task 6 - Case Study Assistance with development of case study components to ensure that winding patterns can be accommodated on the preform winding equipment. * Task 7 - Prototype Manufacture Programming of preform winding equipment. * Task 10 - Technology Assessment Assessment of technical and economic significance of the new software and potential for developing further markets. * Task 11 - Dissemination Assistance with dissemination of the project findings through technical papers and press releases.
Main contactTWINROV A/S
MS. CHARLOTTE OLESEN > DIRECTOR Organisation type > SME |
Contribution to project
* Task 1 - Materials Development Development and supply of thermoplastic yarns * Task 2 - Equipment Development Assistance with fibre handling and feed design.
Expertise
Expertise: the company supplies a wide range of composite products to the Danish markets, including thermoplastic composite yarns. TWINROV have excellent knowledge of processing and market applications for composite materials. Contribution: * Task 3 - Preform Development Supply of materials for the preforms. Advice on fibre handling. * Task 7 - Prototype Processing Provision of materials for production of preforms. * Task 10 - Technology Assessment Contribution to the economic and market assessment for the new technology. * Task 11 - Dissemination Assistance with dissemination of the project results.
Main contactGT GLASFIBER
MR. THOMAS THOGERSEN > MANAGING DIRECTOR Organisation type > SME |
Contribution to project
* Task 4 - Processing Trials Process development for tapered pole sections based on filament wound preforms. This will include machinery modifications and process optimization studies.
Expertise
Expertise: one of Europe's leading manufacturers of FRP flagpoles, they are fully familiar with the design, manufacture, testing and market requirements of composite flagpoles. * GT GLASFIBER have 3 years' experience in processing thermocomposite materials and have filed 1 patent relating to the manufacture of thermocomposite flagpoles. Contribution: * Task 6 - Case Study Specification and design of the flagpole case study. * Task 7 - Prototype Manufacture Production of prototype flagpoles. Process modifications to optimize mechanical and aesthetic properties. * Task 9 - Full-scale Testing Flexural testing of flag pole prototypes. * Task 10 - Technology Assessment Assessment of technical and economic significance of the new processing methodology on the market for flagpoles. * Task 11 - Dissemination Assistance with dissemination of the project findings through technical papers and press releases.
Main contactCANZEAL ENTERPRISES LTD.
MR. BRUCE ELLIOT > MANAGING DIRECTOR Organisation type > SME |
Contribution to project
* Task 2 - Equipment Development Modification to filament winding equipment for the production of tapered and varying thickness preforms.
Expertise
Expertise: the company has been supplying 30 ft fibreglass utility poles into the North American market for over 20 years. CANZEAL have developed and patented new filament winding technology for tapered columns and have comprehensive design and testing facilities for composite materials. Contribution: * Task 3 - Preform Development Development of high speed wound preforms using yarns, tapes and fabrics. * Task 4 - Processing Trials Process development for tapered pole sections based on filament wound preforms. This will include machinery modifications and process optimisation studies. * Task 6 - Case Study Specification and design of the utility pole case study. * Task 7 - Prototype Manufacture Production and supply of wound preforms for the prototype components. Production of prototype utility poles. Process modifications to optimise mechanical and aesthetic properties. * Task 9 - Full-scale Testing Flexural testing of utility pole prototypes. * Task 10 - Technology Assessment Assessment of technical and economic significance of the new processing methodology on the market for utility poles. * Task 11 - Dissemination Assistance with dissemination of the project findings through technical papers and press releases.