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Large Structural Panels Using Thermoplastic Composite

Large Structural Panels Using Thermoplastic Composite. ACMA January 2011. Who Are We A S Composite Inc. is a privately owned Research & Development Canadian company founded in 2003. Products Services Sandwich Panels Continued Research & Development

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Large Structural Panels Using Thermoplastic Composite

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  1. Large Structural Panels Using Thermoplastic Composite ACMA January 2011

  2. Who Are WeAS Composite Inc. is a privately owned Research & Development Canadian company founded in 2003. Products Services Sandwich Panels Continued Research & Development Plates Analysis, Prototyping & Design Moulded Parts Process Development & Fabrication Technology Transfer Thanks to our innovative technology, leading edge equipment, highly qualified, and talented team, we have gained recognition as the leader in this industry

  3. Who Are We • Certification & Patents • Process and machine for producing lightweight thermoplastic composite products in a continuous manner (Patented) • Fibre reinforced thermoplastic composite panel (Patented) • Fibber reinforced thermoplastic composite bridge deck (Patented)

  4. Product • All of our products are based on Thermoplastic reinforced with continuous fibres (composites) Fibre & Matrix • Glass • Thermoplastic • Carbon • Kevlar Thermoplastic Advantage • Extremlylight, non-corrosive, durable, Reusable, Weldable • Better performance, in climates (-40c to 80c) • Impact resistant, 100% Non-Toxic + Environmentally Friendly • Clean Fabrication

  5. What is a Sandwich Panel? • A panel with plastic, metal, paper or other material enclosed between two layers of a different material. • Generally, face plates may be fabricated with stiff materials as compared to the core that is fabricated by materials like plastics, composites etc….

  6. A.S. Panel • Composite (Commingled yarn of polypropylene and fibreglass) used as face plates. • Core material is generally fabricated by PP Honeycomb or Foam

  7. Composite Material Matrix: • Thermoplastic • Thermoset Fiber: • Glass • Carbon • Kevlar

  8. Advantages of Thermoplastic • Clean fabrication • Reusable, reformable, weldable, flexible • Non-toxic and environmental friendly • Better performance in low& hightemperature • More resistant in impact • Low cost

  9. OUR SOLUTION?

  10. Solution Sandwich structure + Using a continuous Process (sequentially heating - compacting - cooling ) = (Innovative Machine)

  11. Solution (Cont.)

  12. Capabilities • Length up to 20 ft and more (7.0 m) • Production rate: 4 ft/min (1.2m /min) • Thickness of panels 0.25 to 4 in (6 to 100 mm) • Core and face plates are fused (not adhered in pp • cores) • Flexibility in forming; drums can be • altered to obtain any desired shape (not just flat)

  13. Advantages of A.S Panel Compared to other alternatives: • Lighter • Easy to transport, to manipulate and to install • Energy dissipation in impact especiallyat low temperature

  14. Applications

  15. Applications Concrete Forming • Easy Manipulation • Durability • Recyclable

  16. Applications Prefab. Housing • Light Weight • Insect Resistant • Water resistant • Rust proof • Flame retardant • Easy Assembly • Permanent Construction

  17. Applications Advertisement Signs • Non-adhesion to ice • and snow

  18. Applications Truck Trailer • Corrosion free • Weight reduction • Recyclable • Non toxic • High impact resistance

  19. Applications • Corrosion free • Recyclable • Easy Manipulation • High impact resistance Guard Rail

  20. Applications Bridge Deck Slab • Corrosion free • Long life span • Weight reduction

  21. Plates & Molded Parts • Thermoplastic polymer reinforced with Fiberglas • 0.5 mm to 6 mm thick • Up to 3mm in width, Unlimited length • Superior to competitive panels such as plywood, steel, Aluminum, Fiberglas, etc Military Applications • Some applications in production throughourpartners • Some applications testedsuccessfully, and ready to beused • Some application undertestingdirectlywith AS Composite • (*More information on testing available upon request due to confidentiality

  22. Structural Performance One floor buildings: Used for wall, roof and floor without any extra structure and can resist harsh climate loadings (ex: abundant snow in Canada, violent wind in Mexican Gulf up to 200 km/hrs, strong seismic load) Two floors and more: • Used as internal and external self supporting walls

  23. Structural Performance(cnt’d) • Bending Strength (3 Points test, ASTM3931): 61.8 Mpa • Compression Strength (ASTM C365): 21.7 Mpa • Impact Strength (Room temperature, appraisedby a falling dart impact test with Ф20 mm spherical head > 250J/m2 • Missile Impact Test TAS 201 based on Florida Building Code results: No penetration in exterior skin

  24. Coating AS Panel Covering AS Panel surface by interlayer (Polyester/Glass fiber mat) during the fabrication process allows a perfect adhesion to: • Concrete • Acrylic Latex Paint • Plaster or other similar materials

  25. Thermal Performance • For 100 mm thick: Minimum R value : R20 = 0.9 m2 ºCJW • No Thermal Bridge in walls or roof • Thermal Stability within -29ºC to 100ºC, 97% Humidity is 2% • Water vapor permeability < 1

  26. Fire performance (usingFire Retardant) Test ASTM E 84-05 Specimen: Panel: 100 mm thick (1.5 mm skin), 0.6 m x 7.3m, core: Fiber Glass/EPS fire retardant Results: Flame spread Index (FSI) 5 Smoke Developed Index (SDI) 135 Time to ignition 502 sec Dripping and flamming Non No Dangerous Gas emited in fire

  27. Fire Performance AS panel may be used as Structural Insulated panel for internal or external walls in Multi floor building if: Coated with fire retardant cover such as: • Ferox 18 mils or • Firetec • Coated with chalk or concrete • Finished with chalk sheet (Dry wall) AS Panels with these coatings meet: • Class A of International Building Code Chapter 8 interior finish, Section 803 • NFPA 5000 Chapter 10 interior finish, section 10.3 • Testing based on ASTM E84-05

  28. Partners • National ResearchCouncilCanada (NRC / IMI) • Sherbrooke University • Massachusetts Institute of Technology (M I T) • British Columbia (UBC)Industrial Material Initiative (IMI)Industrial Research Assistance Program (IRAP)

  29. Opportunities • Unique process and product (patent-pending) • Became a reference of this domain of activity • Creates possibilities for development of new industrial applications • Energize technology transfer

  30. Conclusion Although it seems the A.S. Panels costs more compared to materials like metal and Aluminum, its lower cost for handling, assembly, transportation and maintenance makes it more competitive and efficient on the market.

  31. Think AboutDurability – Cost & Maintenance - Time Think About

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