p. 1 

# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 65 ) 11-1-6 5 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:23 PM

Sheet 65 of 114

### P. 2 

# NSID E jl'^U 

# Mrimm B yDonn*.^ * Qa wson , Senio rEdito r 

# N J ECTIO N DI E PULTRUSION ! ILOSE D SYSTEM , WID E 3PE N TECHNOLOG Y A 945' — 11-1-6 5

!a b floo ri s firs t composit

e rimar ystructur e o n Clas s 8 truc k n d th e bigges

t par t made s o fa r yinjectio n pultrusion . -technologica l advance s i n injectio n di e pultru

sio n ar e improvin g th e T200 0 semi-truc k designe dan dbuil t

b y Kenwort

h Truc k Co . irkland . Wash.) , wit h th e productio n o f asand

- .c h pane l with integrall y pultrude dcor e whic h will rv e a s th e truck' s ca b an dsleepe r floor. In productio n sinc e Octobe r 1996 , th e 2-inch

ic k pane l produce db y Hexce l Industria l ructure s (Kent . Wash. ) i s th e larges t structur e oduce db y thi s proces s t o date . Th e pane l weigh s a t 24 0 I b an dmeasure s 8 8 inche s wid e b y 11 7 che s long . Accordin g t o Rick

Warner , directo r

o f ne w busi

e s developmen t

fo r Hexcel Industria l Structures , e pane l i s als o th e first

composit e primar y struc r e o n aClas s 8 truck , adesignatio n given t o jck s with agros s vehicl e weight o f 33.00 0 l b o r eater . Th e monocoqu e structur e replace s astan ir dmeta l assembl y consistin g o f shee t metal , alu

inu mprofiles , nuts , bolt s an drivets tha t ca n ad d ) t o mor e tha n 10 0 pieces . Kenwort h describe s it s 1000 a s th e next-generatio n Clas s 8 truck , whic h "totally ne w fro

mth e groun dup, " usin g compos - : material s i n th e exterio r aeropackag e an dcab a s fl i a s i n th e sleepe r

interior , both fo

r aerodynam

5 an dt o lighte n th e overal l weight (C T Sept./Oct . )96) . Hexcel' s one-piec e iloo r

design , mad e o

f E-glass

inibrce dviny l este r

laminat e skin s wit

h acor e o f id-grai n bals awood , wo n ou i over adoze n othe r jo r concept s tha t

Kenwort h evaluate dlo r

weight , i n coun t an dassembl y cos t

reductions . Warne r edict s thi s pa n i s afirs t ste p forwardbroade r •ceptanc e o

f larg e composit e structure s fo r majo r jokin g applications . Th e pultrude dpane l provide s a rigidassembl y platformfo r th e cab an dsleepe r

sidewails . whic h bon d t o th e floo

r perimeter . Th e finishe d floo r i s exceptionall y flat , "typically holdin g bette r

tha n 2 m mtoler

ance. " accordin g t o Michae l Zavell . Hexcel' s plan t manager . I

n addition , natura l insulatio n provide d b y th e fiberglass sandwic h structur e significanti y cut s roa dnois e an dhea t los s whe n compare dt o a meta l floor

, earnin g it

th e nam e ThermaCor e Floor . Hexcel warrant s di e floor fo r thre e year s o r 300,00 0 mile s an danticipate s aservic e lif e o f 1.000.00 0 mile s unde r

norma l operatin g condi

tions , accordin g t o Jerem y Hale , engineerin g sale s manage r fo r Hexcel Industria l Structures . 

## INJECTIO N DI E VS . OPE N BAT H PULTRUSIO N Injectio n di e differ s fro mstandar dpultrusio n pro cessin g i n th e wa y th e resi n i s applie dt o wet-ou i th e fibers. Fro mtha t

poin t on . th e processe s ar e Figur e 1 . A n 88-inch-wid e pultrude dmonocoqu

e panel i s th e first

composit e pri

mar y structur e o

n aClas s 8 truck , replacin g th e tra ditiona l multi-piec e meta

l floor assembly i

n Kenwonh' s new T200 0 semi-truck . (Source : Hexcel) .

COMPOSITE S TECHNOLOGY JULY/AUGUS T1997 1 9

### P. 3 WLKmiUli t

n/.-«•.. &* ssentiall y identical . ii I n bot h processes , pultrusio n make s i instan t cross-sectio n part s b y continu

usl y pullin g resin-we t

fiber reinforce-i ! ient s throug h aheate ddie , wher e the 1 ;sin crosslink s an dcures . Th e hear t o f n y pultrusio n machin e i s it s pullin g lechanism . whic h usuall y consist s o f v o hydraulicall y drive n clamping/ I ullin g device s tha t

shuttl e bac k

an d >rth , alternatel y clampin g an dreleasin g i e cure dstoc k

t o pul l i t

dow n th e line 1 it o acuttin g system . Standar dope n bat h pultrusio n wet s u t th e fiber s ahea do

f th e die . pullin g le mthroug h a n ope n resi n bath . Th e 'e t fiber/resi n packag e the n passe s aroug h formin g toolin g an dint o th e eate ddie . I n contrast , fo r injectio n di e ultrusion . preforme ddr y fibers ar e ulle dint o th e heate ddi e an dresi n i s ljecte dunde r

pressur e throug h specia l ori s directl y int o th e close ddie . 

## :LEA N OPERATION , ILEA N AI R ijectio n di e pultrusio n ha s anumbe r o f dvantage s over

open-bat h pultrusion . erhap s th e mos t

importan t

i s th e elimi

atio n o f ope n resi n source s an dnearl y 1 1 styren e emissions . A clos e secon di s liminatio n o

f th e extensiv e clean-u p peration s necessar y durin g an dafte r ar t manufactur e whe n runnin g with pe n systems . Clean-u p o f Hexcel' s lose dinjectio n syste mconsist s mainlyio f leanin g th e injectio n port s an dcleanin g h e di e b y pullin g dr y fiber throug h it . Hal e point s ou t

tha t resi n injectio n als o allow s manufactur e o f part s wit

h lower voi dconten t

an dhighe r

fiber vol

um e an dgive s bette r

contro l o

f fiber alignment . Th e dr y preformretain s it s fiber orientatio n bette r

tha n wet

materia l a s i t enter s th e die . an dth e di e prevent s th e enclose dfibers fro

mshiftin g durin g resi n injection . Hal e emphasize s th e importanc e o

f thi s feature : "W

e tailo r th e fiber reinforcemen t

t o achiev e th e require dstiffnes s i n bot h longitudina l an dtransvers e directions , an dinjectio n give s u s bette r

contro l over

tha t critica l fibe r orientation. " Th e injectio n di e pul

trusio n techniqu e als o represent s ahigh

volume , automate dmanufacturin g proces s tha t

reduce s labo r

cos t whil e pro vidin g reproducibl e qualit y i n finishe d parts . Hexcel manufacture s th e T200 0 floor pane l usin g pultrusio n machiner y designe dan dbuil t

b y CP E Inc . (Haslet . Texas) . Th e machin e use s 100,000

- poun dhydrauli c pul l forc e t o powe r it s tw o shuttle s a t

apre-se t

spee da s the y pul l th e larg e pane l ou t o f th e die . Pull spee dan dothe r

machin e motions , a s well a s al l proces s parameters , ar e controlle d throug h a n Allen Bradle y programmabl e logi c controller . Th e 34.000-lb . 100-inch-wid e di e fits withi n th e pultrusio n machine' s 103

- inch-wid e an d15-inch-dee p maximu m par t size . Th e die' s insid e dimensio n i s 8 8 inches . Designe dan dbuil t

b y CP E i n tw o piece s (to p an dbottom ) fromhar d chrom e plate d414 0 steel , th e bi g di e pose dmajo r

handling , clampin g an d

Cree l syste m fo

r dr y fabric/to w

Preforming guide s Compute r Aide dManufacturin

g

CRTM TM Di e Pinc

h shuttl e # 1 engaged ) 

### I— \ m i T Pinch shuttl e #2 (disengaged ) 

# \* 

# t

. . / Controlling resin injectio n Flyin g cut-of f sa w Finishe d bea

m "tjfur e 2 . CRT M combine s continuou s injectio n di e pultrusio n an dresi n transfer moldin g io produc e conomtcai . hiij h qualit

y laminates . (Source:.Hexcel ) ! 0 COMPOSITE S TECHNOLOG Y JULY/AUGUS T1997 therma l expansio n challenges . I f th e die , whic h expand s whe n heated , i s no t suffi

cientl y filled, exces s resi n ca n buil du p resultin g i n inconsistenc y i n par t size . CP E approache dth e proble mthroug h th e di e tabl e desig n an dauniqu e clampin g syste mwhic h hold s th e to p an dbotto m di e piece s together . Th e final desig n boast s adi e therma l deflectio n o f ±0.00 4 inc h an daflatnes s toleranc e o f ±0.00 2 inch . 

## A COST-DRIVE N PROCES S Usin g th e CP

E pultruder . Hexce l ha s develope dit s ow n proprietar y versio n o f injectio n di e pultrusion . trademarke d CRT M fo r continuou s resi n transfe r molding , an dha s adde dhighl y automat e doff-line system s t o hel p kee p produc

tio n cost s down . Hal e name s cos t a s th e importan t drive r i n thi s development . "CRT M doe s awa

y wit h han dlay-u p o

f preforms , combinin g th e hig h through

pu t rate s o f pultrusio n wit

h traditiona l resi n transfe r

moldm g t o produc e hig h quality laminate s usin g tailore dfabric s an dhig h performanc e resins. " h e says . Thi s make s i t

fa r mor e economica l tha n curren t han dlay-u p approache s use di n RT M an dothe r

moldin g processes. " Hexce l furthe r

cu t cost s i n th e T200 0 floor b y usin g th e lowest-cos t basi c mate rial s —fo

r instance , wove n fabric s instea do

f higher-price dstitche dpre form s fo r strengthenin g th e panel s i n off

axi s directions . Fiberglas s wove n fabri c wit h war p an dwef

t (0 ° an d90° ) fiber

ori

entation , supplie db y Fibe r Glas s Industrie s (Amsterdam . NY} , i s arrange d wit h four plie s o n th e to p an dfour o n th e botto mski n fo

r abalance dlaminat e con struction . Zavel l say s Hexce l save d Kenwort h additiona l cos t

b y precisel y tai

lorin g th e proprietar y fiber architectur e t o mee t transvers e an dlongitudina l stiff

nes s requirements . 

## CRT M MANUFACTURIN G STEP S Th e first ste p i n an y pultrusio n proces s i s t o se t u p an dloadth e materia l deliv

er y systems . Hexce l ha s automate d materia l handlin g startin g a t th e resi n mixin g station . A bas e viny

l este r resin , produce db y Do w Chemica l Co . (Midland . Mich.) , i s automaticall y draw n fro

ma n outsid e bul k storag e tan k

directly int o aday tan k

an d the n int o amixing chambe r locate di n a 

# -y

### P. 4

^ • ;ci

M explosion-proo f

room . Th e resi n i s i y* v , j xe dwit

h filler, mol drelease , curin g agen t h, "' dothe r

resi n syste mcomponents , whic h : als o automaticall y draw n directl y from >rage tank s i n pre-programme d lounts . Th e operato r

simpl y enter s th e desire d sin weight , int o th e programmabl e logic ntrolle r an dth e compute r

control s th e ac t proportion s fo

r mixin g tha t

batc h o f sin . Th e mixe dresi n i s dispense dint o a )se dpressur e pot . Whe n filled, th e po t i s nnecte dt o di e injectio n ports . A s on e essur e po t

run s ou t o f resin , anothe r

i s nnected . Th e completel y close ddeliver y ste mensure s contro l o

f th e resin' s ambi

t t temperatur e an dconsisten t viscosity . Fiberglas s rovin g an dfabri c reinforce

ent s ar e loade dont o rack s an dcreel s i dle dthroug h preformin g guide s tha t ig n th e materia l int o anea r ne t shap e :for e i t enter s th e die . Designin g toolin g i doversize drollers t o kee p th e material s raigh t an drunnin g tru e presente d lothe r challeng e fo

r Hexcel . Th e preform compacte dclos e t o fina

l profil e dimen

on s i n th e initia l sectio n o f th e die . before reache s th e resi n injectio n area , nidirectiona l rovin g i s pulle dthroug h th e de s o f th e panel , alon g wit h wove n fabric , i preven t resi n fromflowing ou t

throug h i e di e enti y o r

exit . A s fabri c run s low , a dmateria l fromne w roll s i s attache dt o i e en do f th e previou s rol l b y bondin g :ri mcloth acros s th e tw o joinin g edges , a andar dtechniqu e i n pultrusion . Zavel l ay s Hexce l engineere dan dbuil t al l infee d >olin g an di s workin g o n "splice-and-run * :chnique s tha t

woul dallo w totall y auto late dmateria l delivery . Hexce l receive s preshape d88-inc h ide . 4-f t long , 2-inc h thic k

bals asheet s •o mDiab' s ProBals aDivisio n (DeSoto . exas ) stacke d2 0 sheet s t o apallet . Th e allet s ar e loade dont o a10

- t o 15-ft-lon g hain-drive n trac k

whic h pull s the mint o •ositio n fo r deliver y t o th e die . Fou r

ful l •allet s a t atim e fee

dont o ascisso r

jac k i n

. loadin g mechanis madjacen t t o th e pul

rusio n machine . Tli e loadin g mechanis m >ulls th e to p shee t

fro mth e to p palle t

and .

. s eac h shee t

i s removed , th e scisso r

jac k aise s di e nex t

shee t int o positio n fo

r emoval . A bondin g adhesiv e i s applie dt o h e leadin g edg e o

f di e core , whic h i s mshe du p agains t

th e precedin g piec e o

f >als at o maintai n continuity . A senso r sig

lal s ch e controlle r

t o remov e eac h palle t

a s t i s emptie dand . whe n tli e stac k o f bals a i n th e loadin g mechanis mrun s low . anothe r senso r signal s th e controlle r

t o brin g u p fou r

ne w pallets . Th e bals ai s conveye ddow n th e lin e throug h stationai y gi b saw s tha t tri mth e edge s t o ensur e consisten t widt h o f th e material . Th e dimensio n o f th e core i s critica l t o th e proces s a s wel l a s t o th e eco nomics.' * Zavell explains . "A core that' s to o wid e o r to o thic k ma y ja mth e die . an don e that' s to o narro w o r

to o thi n ma y no t

ade

quatel y bon dt o th e ski n laminate , allow

in g resi n flows t o fill u p th e gap . drivin g materia l cost s u p an daffectin g weigh t an d physica l propertie s a s well. " Afte r trim

ming , th e loadin g mechanis mdeliver s th e cor e directl y int o th e die . Afte r th e initia l loading , th e machin e i s prepare dfo

r start-u p b y pullin g th e rein

forcement s throug h th e ope n die . The y ar e tie dof f o n arigidbar . whic h i s place di n th e firs t shuttle . The n pulle r

speed , di e heat , resi n injectio n pressur e an dothe r (proprietary ) proces s parameter s ar e entere dint o th e programmabl e logi c con troller . Al l parameter s ar e computer-con trolle dan dmonitore db y multipl e sensors . Finally , th e di e i s close dan dth e machin e i s read y fo

r start-up . Th e actua l processin g start s wit h resi n wet-out . Resi n i s pumpe dfromth e pres sur e po t an dflows int o th e dr y prefor m throug h multipl e injectio n port s locate do n th e to p an dbotto mo

f th e injectio n die . Afte r preliminary wet-ou t

nea r th e di e entiy . th e partiall y impregnate dprefor mi s pulle dthroug h atapere dregio n i n th e di e tha t graduall y compact s th e materia l int o th e final par t

configuration . A multi

dimensiona l resi n flow surround s th e fiber s an dthoroughl y saturate s the ma s the y ar e compacted . Followin g wet-ou t

i s th e curing/mold

in g process , whic h occur s i n conjunctio n wit h th e pullin g operation . Th e impregnat

e dprefor mi s pulle dint o th e die' s cur e region , wher e th e temperatur e profil e i s controlle di n severa l hea t zones . Die hea t i s rampe du p t o 175° Fan dthe n t o 245 3 F throug h multipl e zone s fro mth e di e entry , an ddow n agai n a t

th e exi t t o tighte n con tro l over gel . crosslinkin g an dfinal cure . Di e temperatur e i s closel y linke dwit h pul l spee dan dinjectio n pressure , s o i f th e temperatur e profil e i s changed , a s agen eral rul e th e other s mus t b e adjuste da s well . "I f you'r e pullin g faster , yo u nee dt o cure more quickly , s o yo u nee delevate d temperature s or

alonge r cur e zone. " Zavell explains . "Yo

u als o nee dt o increas e th e deliver y o f th e resi n (injectio n pressure ) i n orde r t o increas e runnin g speed. " Th e cure dproduc t

cool s a t ambien t tempera tur e betwee n th e di e exi t an dth e shuttle . Th e final ste p o

f th e pultrusio n proces s i s par t cut-off , whic h i s accomplishe db y a singl e 34-inch-diamete r diamon dblad e mounte do n aflying cut-of f sa w sectio n a t th e downstrea men do

f th e machine . Th e compute r i s signale dt o initiat e th e cu t whe n th e pane l reache s apre-se t length . Th e sa w sectio n i s synchronize dwit h pullin g spee dt o trave l downstrea mwhil e th e blad e cut s acros s th e widt h o f th e panel . Becaus e o

f th e siz e an dweigh t

o f th e part . Hexcel ha s reduce dmanua l handlin g t o aminimum . I n a n automate dtake-of f syste mtha t

i s similar

t o th e core deliver

y system , th e cu t

pane l i s remove dfromth e sa w an dconveye ddirectl y t o apalle t an d scisso r jac k o n achain-drive n conveyor . Th e panel s ar e the n conveye dt o asepa rat e scissor-jac k

loadin g system . Thi s sys te memploy s a n ovenheadvacuu mshuttl e an dvacuu mcup s t o pick u p th e to p pane l an dlocat e i t

i n th e compute r

numericall y controlle d(CNC

) equipmen t

fo r secondar y fabricatio n trimmin g an ddrilling . Th e fab

ricate dfloor

panel s ar e similarl y vacuum remove dfro mth e cuttin g tabl e an d stacke do n anothe r

scisso r jack/pallet . Th e edge s o

f th e cor e ar e the n seale dan d th e panel s ar e packe dfo r shipmen t

t o Kenworth' s assembl y line . Hexce l i s producin g abou t 4 5 floor pan el s pe r da y wit h maximu mcapacity esti

mate dt o b e 9 0 floors pe r day . o r approxi

matel y 87 5 linea r

ft o f pultrude dpanels . Zavell claim s tha t

heat , pressure , an dpul l spee dar e no t

pacin g factor s a t

thi s time . "Th e bottlenec k

ha s no t bee n th e pultru

sio n process : it' s bee n downstrea mtrim

ming , sealin g an dpackin g operations . We'v e bee n abl e t o increas e th e spee do f th e CN C b y usin g creativ e cuttin g tools. " h e says , addin g tha t

thi s techniqu e wa s somethin g th e compan y spen t alo t o f tim e developin g an dth e approac h i s highl y pro prietary . "As w e continu e t o improv e CNC . spee dan dothe r

downstrea moperations , we wil l wor k o n increasin g pultrusio n speed , with di e ultimat e goal o f doublin g ou r productio n rate. " h e explains . 

## $10 0 MILLIO N MARKE T Th e Kenwort

h floor-production contrac t mark s amileston e i n Hexcel' s global strategi c pla n t o diversit

y fro mit s rol e a s COMPOSITE S TECHNOLOGY JULY/AUGUS T199 7 

### 2 5STE P l a STE P l b 

## R3_

vlateria l deliveiy : Resi

n i s neve r expose dt o th e environmen

t throughou t

com- Reinforcement s ar e loadedont o rack s an dcreel s an dle

dthroug h preforming puter-controlle dmixing , deliver y t o th e machin e an dinjection int o th e die . guide s an droller s t o prefor mnea r ne t shape s befor

e di e entry . STEP1 C STE P 2

Bals acor e i s edge-trimme dan ddeliveredt o th e di e withou t

an y manua l han

dling . Resin injection : Resi n i s injecte

dint o th e prefor

mthroug h multipl e port s 0 1 th e top an dbotto mo

f th e die . STEP3 A STEP3 B

Moldin g an dpulling : Th

e material cure s i

n the heate ddi

e an ddi e 88-inch

wide . 2-in-thic k

molde dsandwic h panel exit s th e die . Reciprocatin g shuttle s wit h 100.000-l b pul l forc e continuousl ypul l Ui e p ; el s ou i o f th e die . 

# H

### P. 6

STE P 4 STEP 5

it-off : Sa w secUo n travel s downstreamwit h th e par

t while acircula

r blad e t s th e pane l t

o length . Off-lin e finishing : Automati c handlin g system s mov e th e pane l offline fo

r CN C trimmin g an ddrilling , sealin g an dpackaging . 

### producer o f high-performanc e composit e material s an dstruc xe s fo r th e aerospac e industr

y b y applying it s expertis e t

o non - :rospac e transportatio n an drecreatio n businesses . Warne r une s th e company' s target market s fo

r th e CRT M proces s a s las s 7 an d8 trucks , infrastructure , marine/offshor e an dship

n g containers . H

e estimate s tha t

thos e segment s represent

an 'eral l annua l market

o f $5 0 t o $10 0 million . "Since th e growt h potentia

l i s highl y relate dt o th e succes s o

f Kenworth' s innova

tiv e T2000 truck , w

e ar e optimistic about

th e long-run potentia

l fo r CRT M i n thi s market

segment. " Wame

r says . For more information, circle the number on the Reader Service Card: core, 274 ; reinforcements, 275 : vinyl ester resin. 276 ; pultrusion equip.. 277 . 

# Composite s Manufacturin g Doesn' t Hav e T o B e A n Ar t

MM " 

### J

* ^ 

# liqui d Contro l <or p liw.orative Dispensing Solutions 

### Fo ran yproces s .. . Han d Lay-u p Resi n Transfe r Moldin g Filamen t Windin g Pultrusio n Compressio n Moldin g Castin g Bondin g Sealin g 

### o rproduc t Industria l Commercia l S p o rts /

L e is u r e Transportatio n Aerospac e Militar y Marin e Bathwar e Corrosio n Architectura l Liqui d Contro l Corp . take s th e guesswor k ou t o f achievin g th e accuracy , reliabilit yan d perfonnanc e yo u nee d fo ryou rcomposite s manufacturin g processes . Ou runiqu e Posiload * positiv e displacemen t meterin g technolog yca n handl e mos t plura l componen t resi n systems , adhesives , sealant s an d syntacti c com - pounds . Discove rth e advantage s tha t thi s technolog y offer s fo ryou rspecifi c composite s applicatio n b y callin g (330 ) 494-1313 . As k fora fre e cop yo f ou rMeter , Mix , # ! Dispens e Engineerin g Handboo k i Freedom Ave. N

W • P.O . Bo x274 7 • North Canlo a Ohi o 44720-074 7 • Rion e (330

) 494-131 3 • Fa

x(330 ) 494-538 3 Circl e 11 8 o n th e reade rservic e car d COMPOSITE S TECHNOLOG Y miy/.AMIDS T IOQ 7 2 7