■ Compiled by Jessy Lu
JEC創新獎
JEC創新獎是一項歷史悠久的全球計劃，該獎項秉持3 個目標：識別，推廣並獎勵世界上最具創新性的複合材 料解決方案在過去15年間，JEC創新計劃已覆蓋全球 1800家公司;其中177家公司和433位合作夥伴因在複 合材料方面的卓越創新而榮獲創新獎，JEC創新獎的評 定以合作夥伴在價值鏈參與度，創新成果在技術或商業 方面的應用等要素作為評判標準，頒發給複合材料生產 方面的佼佼者。 The JEC Innovation Awards is a long-established and worldwide program with 3 simple goals: identify, promote and reward the most innovative composite solutions in the world. Over the past 15 years, the JEC Innovation Program has involved 1,800 companies worldwide; 177 companies and 433 partners have been rewarded for the excellence of their composite innovations. The JEC Innovation Awards reward composites champions, based on criteria such as partner involvement in the value chain, technicality or commercial applications of innovations.
Surface Generation主要汽車複合材料創新獎
由Engenuity Ltd（ENG）設計並由Surface Generation Ltd（SG）製造的複合材料獲得了汽車板塊的JEC創新 獎該材料為C柱加強件利用熱塑性包覆成型原理，實現 車輛白車身（BIW）結構性能的飛躍。（如圖1）
The composite C-Pillar reinforcement component, designed by Engenuity Ltd (ENG) and manufactured by Surface Generation Ltd (SG), exploits the principle of thermoplastic overmoulding to achieve a step change in structural performance of the vehicle body-in-white (BIW). (See Photo 1)
也就是說，我們僅僅需要在使用負載路徑的局部區域 合理使用高性能，均衡，連續的纖維增強材料，便可 以進而將整體部件的成本降至最低，在其他的一些可 應用區域，可以使用更實惠的短纖維增強材料實現複 雜性能，通過幾何形狀增加零件剛度並實現裝配。 That is, to make judicious use of high performance, aligned, continuous fibre reinforced material only in localized areas where load paths demand their use, thus minimizing the overall part cost. Elsewhere, more affordable short fibre reinforced material is used to realize complex features that add part stiffness through geometry and enable assembly.
該組件的幾何形狀複雜且厚度可調整（2mm至 8mm），它包括四個使用短纖維（SF）增強特殊PA 尼龍（KDFeddersen，AKROLOY®PAICF 40）包覆成 型的連續纖維（CF）增強 PA6（SGL Group，Sigrafil C T50）嵌件，使用電子塗覆工藝完成對該組件的塗覆後，將其黏合到白車身，CF嵌件由預先加固的有機 薄片沖壓而成，該有機薄片採用高正交各向異性層壓 板堆疊製成，以適應部件在使用中的承載。（如圖2） The component possesses complex geometry and variable thickness (2mm to 8mm). It comprises four inserts of continuous fibre (CF) reinforced PA6 (SGL Group, Sigrafil C T50) overmoulded with a short fibre (SF) reinforced PA6 compound (K.D. Feddersen, AKROLOY PA ICF 40). The component is adhesively bonded to the BIW after its e-coat process. The CF inserts are stamp formed from a pre-consolidated organosheet produced with a highly orthotropic laminate stacking sequence to suit the in-service loading of the component. (See Photo 2)
零件的一部分在模具中冷卻，另一部分在外部夾具內 冷卻，SG和ENG共同合作開發了多種測試方法，用 以獲取與包覆成型材料和連續纖維增強嵌件之間的黏 接強度相關的最優工藝條件，PtFS是針對雙色射出前 所需達到的熱力狀況而開發。 The component is cooled partly in mould and partly within an external fixture. SG and ENG worked together to develop test methods that would enable the optimum process conditions to be established in relation to the bond strength between the overmoulding material and the continuous fibre reinforced inserts. PtFS technology was exploited to achieve the necessary thermal conditions prior to overmoulding.
成型模具的表面由SG實施的分析研究進行調整，以 補償工藝加工引起的變形，CF嵌件安裝在包覆成型 模具中，該模具由SG設計製造，並採用其獲得專利 的“PtFS”熱控制技術，關閉該工具之後，開始對96 個加熱器/冷卻器通道進行分區並優化熱循環。 The moulding surfaces of the forming tools are adjusted, using output from analytical studies conducted by SG, to compensate for process induced distortion. The CF inserts are positioned in the overmoulding tool. The tooling is designed and manufactured by SG and incorporates their patented “PtFS” thermal control technology. The tooling is closed and each of the 96 heater/ cooler channels are zoned and their thermal cycle optimized.
ICF產品優勢
•質量更輕：質量比使用最新型金屬解決方案製成的零件減少了30％
•經濟降本：淨邊模鑄複合材料零件價格為* 19歐元/公斤
•可回收：我們的再生纖維可使材料進行重複生產
•適用於多種行業：設計解決方案為行業的多樣性變化創造機會
•價值傳遞：ICF碳纖維增強產品組合不僅參與促進相關行業的發展，更為我們的客戶提供產品生產的新思路
Key Benefits • Lightweight: A 30% mass saving over the state-of-the-art metallic solution • Affordable: A net edge moulded composite part at €19/kg • Recyclable: Recovered fibre supporting a material suited to reprocessing • Adoptable: A design solution creating opportunities for platform variants • Transferable: Technology benefitting both industry and consumers
參與專案的合作夥伴
Engenuity Ltd（英國）: http://engenuity.net/ InCA Technology（瑞士）: https://www.inca.technology/ K.D.Feddersen UK Ltd（英國）: https://kdfeddersen.com/
