Toho Tenax

Product family
Dry Reinforcements DR

Rodrigo Cesar Berardine Sales and Marketing Manager

Toho Tenax America
April, 07. 2014, R. Wockatz (MP) 1
 Content

1. Background and Motivation

2. Non-Crimp Fabrics Tenax DRNF
3. Woven Fabrics Tenax DRWF
4. Tenax Toughener Development
5. Outlook

April, 07. 2014, R. Wockatz (MP) 2

 1. Background and Motivation

Increasing requirements for future Aerospace and Automotive

developments in terms of performance, weight, cost and environmental
requirements drive new material needs.
To meet growing demand for composites the current available materials
themselves are now borderline to fulfil the given requirements.
Prepreg materials which are the baseline reference and normal first
choice material esp. in Aerospace are problematical in terms of highly
complex parts (tolerances etc.) and large production volumes.
Textile technologies in combination with resin infusion processes
are offering significant potential in manufacturing processes for
high production rates, integral structures and flexibility but to date
with some disadvantage in mechanical properties.

April, 07. 2014, R. Wockatz (MP) 3

 2. Non-Crimp Fabrics Tenax DRNF

Advantages
Strength and stiffness in multiple directions (possibility to optimize weight
distribution and minimize material costs)
Adapted areal weights (low <-> heavy) achievable for minimizing waste for
complex lay-ups (cross plies)
Areal weights using high tow counts (12K & 24K) in established prepreg
thicknesses now possible
Reduced processing costs
Very low level of misalignment

Disadvantages
Mech. Properties nearly matching Prepreg baseline levels

April, 07. 2014, R. Wockatz (MP) 4

 2. NCF Development Tasks

Therefore Toho Tenax initiated on-going development activities within the last years
to solve these issues and provide in partner cooperation new solutions to the market
Tenax Dry Reinforcements.

Major tasks for improvements have been :

Lower and flexible adaptable areal weights (based on high tow count CF, 12K+)
Improved preforming and toughness properties
Adapted/flexible drapeability incorporating sufficient permeability
Mechanical properties equivalent to todays Prepreg baseline
Low material bulk factor for preforming (e.g. for complex RTM tools)
High fibre volume content (target 58% +/-4%) even with toughened and powder
bindered material in infusion technology

April, 07. 2014, R. Wockatz (MP) 5

 2. Tenax NCF improvement program

Prepreg-Reference

NCF beginning of Latest NCF Tenax Dry

NCF ca. year 2005
year 2000 Reinforcements (DRNF)

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 2. Tenax NCF improvement program
Bidiagonal-NCF (+/- 45), 268gsm (134gsm per layer), stacking [(90/0)8]S
Tenax-E IMS65 E23 24K 830tex, Test in acc. to EN 6036
800

700
Very close
600
Strength [MPa]

500

400
or better to Prepreg level
NCF SoA
300
Prepreg
200
Latest
New NCF
Tenax NCF
100

0
Compression plain OHC
April, 07. 2014, R. Wockatz (MP) 7
 2. NCF technology General details

all developments are based on latest NCF technology available in the market
cutting edge technology especially for Tenax-E HTS45 E23 12K, 24K and
Tenax-E IMS65 E23 24K carbon fibres
up to 5 layers in only one production run possible to lay down
areal weights from ca. 70gsm per layer upwards possible (depends on CF type)
fixed material width of maximum 1.27m (50)
cutting technology available -> 5 cutter, e.g. for cutting 5 x 254mm (10) stripes
roll length flexible (customized, typically 40m - 70m, depends on weight)

April, 07. 2014, R. Wockatz (MP) 8

 2. NCF technology Possible building blocks

e.g. Non-woven
Stitching yarn for Toughening

Creel material
(warp & weft)
Tenax-E IMS65 E23 24K
Tenax-E HTS45 E23 12K
Tenax-E STS40 F13 24K, 48K
April, 07. 2014, R. Wockatz (MP) 9
 2. NCF technology technical details

Typically NCF stacking's are:

Bidiagonal (BD)
e.g. +30/-30; +45/-45; +60/-60;
Biaxial (BA)
e.g. 0/90; 90/0
Triaxial (TA)
e.g. +30/90/-30; +45/0/-45; +60/-60/+60;
Quadaxial (QA): e.g. +30/90/-30/0; +45/0/-45/90 ;
Multiaxial: e.g. 0/+45/0/-45/90
Possibility to add toughening system (veil) on each CF layer incl. as the first
layer (Bottom) and the last layer (Top).
Both outer layer can be Powder Binder coated for additional preforming
abilities.
April, 07. 2014, R. Wockatz (MP) 10
 2. Tenax NCF Product benefits
Smooth and even material surface quality with
lowest grade of material undulation
Lower and flexible adaptable areal weights possible
Improved preforming and toughness behaviour
allowing excellent mechanical properties
Adapted drapeability even for complex shaped parts
Mechanical properties matching todays Prepreg
baseline due to very straight and parallel fibre
alignment
Low level of material bulk factor for preforming
High fibre volume content (~58%) even with
toughened and powder bindered material in infusion
technology (e.g. via pure vacuum process, like VAP)
demonstrated
April, 07. 2014, R. Wockatz (MP) 11
 3. Woven fabrics Tenax DRWF

Specialised Woven Fabrics are still needed for future (aerospace)

applications.
In a close cooperation with partner companies several materials are now
ready to market:

UD woven fabric with high carbon fibre alignment and optimised

permeability in a broad range of fabric areal weights as well as fields of
applications.
Curved fabric materials which can be adapted to complex shape of
parts
Modified standard woven fabrics with target of high material
toughness improvement as well as improved preforming abilities
Lightning strike protection (LSP) material based on material
combinations and areal weights
April, 07. 2014, R. Wockatz (MP) 12
 3. Woven Fabrics UD fabric

This newly developed material is dedicated for high performance application,

where high carbon fibre alignment and optimised permeability are key features.
A broad range of fabric areal weights as well as fields of applications may be
targeted a combination with non-wovens and powder binders are possible
too. 2600
Tenax-E DRWF-UD + RTM6
2400

2200 180C 3rd gen. Epoxy Prepreg

2000 Carbon Fibre: Tenax-E HTS40 12K 800tex

Areal Weight: 134gsm per layer
1800

1600
Strength [MPa]

1400
1mm
1200

1000

800

600

400

200
New UD
0
Woven fabric Tension Strength Compression Strength OHC
(EN 2561 B) (EN 2850 A1) (EN 6036)

April, 07. 2014, R. Wockatz (MP) 13

 3. Woven Fabrics Curved fabric

For complex and curved designed parts, e.g. fuselage frames, the
drapeability of fabrics is limited.
A specialised material was developed within a close partner cooperation
which can be adapted to individual shapes and
guarantee best performance and fibre alignment.

UD-fabric adapted for

UD-fabric with high drapeability curved parts
April, 07. 2014, R. Wockatz (MP) 14
 3. Woven Fabrics Curved fabric
Product benefits
Curved UD-fabric
Excellent performance due to straight fibre
alignment
CF areal weights between 100 500gsm
(depends on CF type) possible
Radius of min. 50mm upwards possible
Fabric width min. 10mm max. 350mm
Roll length customized (typically 50-100m)
Toughness improvement (e.g. via non-
woven) possible
Preforming improvement (e.g. via powder
binder) possible
April, 07. 2014, R. Wockatz (MP) 15
 3. Woven Fabrics Lightning Strike Protection

April, 07. 2014, R. Wockatz (MP) 16

 3. Woven Fabrics Lightning Strike Protection

April, 07. 2014, R. Wockatz (MP) 17

 3. Woven Fabrics Lightning Strike Protection

Lightning strike tests

Powdered LSP passed successful!
Many fabric combinations
Woven fabric
(style/weights) are possible.
April, 07. 2014, R. Wockatz (MP) 18
 4. Tenax Toughener developments
Based on before showed test results, materials were combined and tested
to verify mechanical performance.
Testing reference is a newly developed high performance UD woven fabric
which allows laminate stacking for each test methods.

Fabric
Laminate Carbon fibre Resin Binder Toughener
style
1mm

1 UD Tenax - E w/o
Momentive
woven IMS65 E23 24K Momentive
EP05311
fabric 830tex EPS 600
2 ~7 g/m with
194 g/m

New UD Woven fabric

April, 07. 2014, R. Wockatz (MP) 19

 CAI 3x30J, AITM 1.0010,
UD-Fabric, 194gsm, Tenax-E IMS65 E23 24K 830tex,
Resin EPS600, Stacking [+45/0/-45/90]3S

320 4800

280 4200
CAI - Residual Strength [MPa]

240 3600

CAI - Damaged Area [mm]

200 With 3000
Tenax
160 Toughening 2400
System
120 1800
w/o
80 Toughener 1200
Residual Strength

40 600
Damaged Area
0 0
Laminate 1 Laminate 2
April, 07. 2014, R. Wockatz (MP) 20
 4. Toughener Development
Moisture uptake [EN3615] of Tenax toughening system

No additional water/moisture uptake

No left moisture after dry back procedure

April, 07. 2014, R. Wockatz (MP) 21

 5. Outlook

Toho Tenax is keen to support customer requirements for new textile

specialised materials.
Combinations of building blocks are always possible to meet
particular customer needs.
Material combinations for components may include Non-crimp fabrics,
Powdered
(UD)-Woven fabrics as well as LSP
Non-woven (Toughening) to fulfil given
Woven fabric
requirements like high Toughness performance as well as preforming
abilities.

April, 07. 2014, R. Wockatz (MP) 22

 Thank you for your
attention!
Powdered LSP
Woven fabric

April, 07. 2014, R. Wockatz (MP) 23