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The Coating Machinery Experts
Resin film coating and prepreg impregnation
technologies for thermoset prepreging solutions
Andrea Glawe, Frank Schfer
KROENERT GmbH & Co KG
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Agenda
The company-group KROENERT BMB DRTYEC
Product information
Reinforcement
Matrix
Technology and coating line concepts
Handling technologies
Coating technologies
Summary
KROENERT GmbH & Co KG
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The Coating Machinery Experts
The company KROENERT
1903: foundation of Maschinenfabrik Max Kroenert
manufacturing of tailor-made machines for over 100 years
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The Coating Machinery Experts
The company KROENERT
Accomplishments
Foundation of Maschinenfabrik Max Kroenert 1903
First wax and paraffin machine for coating and lamination 1922
First aluminium and paper laminating machine 1936
Wet and wax laminating of flexible packaging 1952
First RECO built for dry bond laminating 1958
First pressure sensitive (PS) adhesive line for
labels based on hotmelts 1968
Development of PAK 400 for (PS) hot-melt
coating 1973
Development of solvent-free dry bond lamination
(one- and two-component adhesives) 1975
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The Coating Machinery Experts
The company KROENERT
Accomplishments (continued)
Development of PAK 400 EP for
applying epoxy resin (1400mm) 1984
Development of MPG 600 CI System 1994
Commissioned widest and 1998
fastest R&D Line in converting industry
(subsequently installed in Canada in 2003)
Extension of R&D centre with a second
R&D Line for hot-melt and UV-curable acrylics 2002
Start-up of worlds widest (1300 mm / 51) 2004
and fastest (1610 m/min / 5280 fpm) R+D Line
in converting industry
Continuous width change of MWC-Coater 2007
(patent)
Sleeve type for gravure rollers 2008
LabCo launched to market-> from FAB TO LAB 2009
Installation of LabCo at KROENERT R&D centre 2010
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The Coating Machinery Experts
The company KROENERT
KROENERT GROUP
DRYTEC
Norderstedt, GER KROENERT
Hamburg, GER
Bachofen + Meier
Blach, CH
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The Coating Machinery Experts
The company KROENERT
KROENERT GmbH & Co KG
Privately owned
400+ employees in the Group
Expertise
Research + Development
Tests in Technology Centre
Sales
Engineering + design
Production + installation
Erection + commissioning
Service
Competence Centre for
development of coating stations
Hamburg, Germany
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The Coating Machinery Experts
Product information
Application trends from JEC 2012
Trends in:
Aerospace (Dreamliner B 787 and Airbus A 350 with high
volume of composites new production facility for wings)
Wind energy plants (Renewable energy standards and offshore
installations power five-fold surge to $15.4 billion, says Lux
Research, Dec. 2011 or Wind Surpasses Aerospace as Top
User in an Advanced Composites Market Worth $26 Billion in
2020)
Automobile (BMWi -born electric)
Railroad
Ships
Sports/Leisure
KROENERT GmbH & Co KG Source of pictures: webside company Airbus, Boing, BMW
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The Coating Machinery Experts
Product information
Reinforcement
Man made fibers
Carbon
Glass
Polyamide (Nylon)
Aramid (Kevlar)
Basalt
High stable Polyethylene (Dyneema)
Hybrid Structures (Mixtures of Glass / PA or PE)
Natural fibers
Linen
Hemp
Sisal
Wool
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Product information
Reinforcement
Structures
Rovings with different K Substrates
(Number of filaments 1 K = 1000 single Bi-directional structures woven
filaments) fabric
Single Rovings are processed to a Multi-directional structures
closed tape
laying structures
knitted structures
combination with non-
woven.
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Product information
Matrix
Two types
Thermoplastic materials (hotmelt) Duroplastic materials (thermo setting
materials)
Polyamide PA 6, 6.6 or 12
solvent or water based epoxy resins
Polyether ether ketone PEEK
Polyester resins
Polyolefin PE or PP
Phenolic resins
Polycarbonate PC
Vinyl ester resins
Polytetrafluroethylene PTFE
Acrylate or Polyurethane resins
1- or 2K curing products
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Product information
Matrix - requirements
Duroplastic products
Temperature range 250 C, usual application temper ature 60 120 C
Viscosity range 1 200 Pas depending on chemistry
Coating weight both sides 10 300 g/m
Average speed for film production 50 80 m/min
Average speed for impregnation 5 20 m/min
Temperature accuracy +/- 1 K
Thermoplastic products
Temperature range 80 4000 C
Viscosity range 100 500 Pas depending on chemistry
Coating weight both sides 10 300 g/m
Average speed for film production 50 80 m/min
Average speed for impregnation 1 5 m/min
Temperature accuracy +/- 1 K and constant high pressure for impregnation
process
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Process technology
Three different process technologies possible:
1) Tape and resin production and lamination / impregnation in two different processes.
2) Combination of resin application and lamination / impregnation in one production
line with two coating systems for top and bottom resin layer.
3) Direct coating / impregnation with water based and solvent based matrix materials.
Pros and cons for a two step process Pros and cons for a one step process
+ Resin film process and impregnation + Resin film process and impregnation in one
separates and independent. step less heat stress for resin .
+ No stop of one process if other one doesnt + Lower volume of silicone paper necessary.
work. Resin film production with lower speed and
+ With one coating line can be feed more then thereof longer staying time in application
one impregnation line. system.
Resin film have to be melted again before If one process is not working well the other
lamination. one will be negatively influenced as well.
Higher volume of silicone paper or double Higher investment for two coating unites.
side silicone paper necessary
Higher investment for two plants.
Ideal solution for production. Ideal solution for research and development.
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
KROENERT technology PAK 400 EP
for resin film coating with single winding technology with lamination
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
KROENERT technology PAK 400 EP
for resin film coating with turret winding technology
KROENERT GmbH & Co KG
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The Coating Machinery Experts
RECO EP tape impregnating line
layout (example)
Processing of all types of tapes/rovings in varying quality and with different resin contents
Controlled unwinding tension of spools
Optimized feeding of tapes/rovings
Maschine
nfabrik Max Kroenert
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The Coating Machinery Experts
RECO EP fabric impregnating line
layout (example)
Processing of all types of fabrics in varying quality and with different resin contents
Controlled unwinding and rewinding tension of materials
Optimized feeding of fabric and material
Maschine
nfabrik Max Kroenert
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The Coating Machinery Experts
RECO EP vertical impregnating line
layout (example)
Individual profiles for air
circulation and temperature
control in the dryers for the
prevention of skin formation
Systems for heat recovery and
exhaust air treatment
Maschine
nfabrik Max Kroenert
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The Coating Machinery Experts
Process description
Winding technology
Tension adjustment from unwinding to rewinding process
Tension for each roving bobbin winding station: 100 400 g
Tension increase during spreading process: 5 N / 1 m Breite
Release and foil: 10 1000 N
Substrate tension unwind: 25 300 N
Substrate tension finished product rewind: 300 3000 N
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Winding technology
Unwinds and rewinds developed and produced by the KROENERT Group for all coating
and laminating lines.
Also may be integrated into machines of other suppliers.
Range of winders encompasses not only standard requirements, but also winders for
individual requirements, e.g reduction of wastage or handling of delicate materials.
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Winding technology
unwind (with shaft and edge control) turret unwind
shaftless unwind turret rewind
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Coating stations are performance centers of a coating line.
KROENERT covers all coating methods available.
Mechanical precision with integrated, state-of-the art
drive and controls:
Achieving accurate roller speeds.
Securing highest precision in coatings.
Guaranteeing highest production quality.
Modular design.
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Direct or indirect roller application
Viscosity range: up to 200 Pas possible but with high pressure between rollers
or three/four roller system for thin layers.
Temperatures: up to 250 C, accuracy of +/-1 K necessary
Coating weight: 10 300 g/m2 depending of viscosity and coating technology
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Direct or indirect roller application
Highest temperature accuracy for resin
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Extrusion
Viscosity range: up to 500 Pas possible but only with extrusion pumps
Temperatures: up to 400 C, requested accuracy +/- 1 K
Coating weight: 10 400 g/m depending on viscosity and technology
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Commabar technology with heated commabar)
Viscosity range: 0,1 up to 100 Pas theoretical possible
Temperatures: heatable roller as well as commabar requested accuracy +/- 1 K
Coating weight: 10 1000 g/m depending on viscosity and technology
Accuracy: very high - > non-bending commabar
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Dipping technology
Viscosity range: very low between 0,01 1 Pas,
Instable fiber construction will be destroyed if viscosity is
to high. In case of UD, dipping roller will be not moved
because of danger of winding fibers around roller.
Temperatures: up to 250 C
Coating weight: depending of substrate
as well as gap between
squeezing rollers
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Coating technology
Features*:
high precision rollers with rolling contact bearings and minimal tolerances (< 2m at 90C)
chromed or ceramic coated surfaces of coating/ metering rollers
bending compensation of coating/metering rollers: max. 2,5 m deflection
precise temperature control of coating/metering rollers: +/- 1 K
accuracy in roller adjustment + positioning: +/- 1,5 m (hydraulic)
manual or automatic positioning of rollers
quick change over of backing roller (also sleeve possible)
minimum gap: 40 m at 90C
antistatic coating of parts in contact with resin
accurate tension control of web
good accessibility of coating station
* remarks: depending on requirements as well as layout of station
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Conditioning technology
Heating table one or both sided
- Guaranteed contact between heating table and laminated compound of paper /
prepreg / paper or film
- Temperature accuracy of +/- 1 K requested
- PTFE-coated heating tables or covered with changeable PTFE protective film to
avoid adhering of resins
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Cooling technology
Convective or contact cooling
Cooling of heated web to defined temperature
Cooling station comprises cooled steel roller and pressure roller
Temperature variation +/- 1 C
Size and numbers of cooling rollers varies
Also air coolers or cooling plates can be used
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Laminating technology
Possible technologies
3-roller
Vertical
2 roller
Horizontal
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Nip laminating and delaminating technology
Covering all applications with 2 roller technique
Tempering/cooling of plates and rollers
High precision rollers with minimal tolerances of < 2m
Bending compensation of rollers
Accuracy of roller adjustment +/- 1,5 m (hydraulic)
Consistent and reproducible nip settings (nip pressure and gap measurement)
Precise temperature control of rollers, heating and cooling plates of +/- 1C
Horizontal compacting nip arrangement with heating and cooling plates
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Slitting technology
Accuracy parameters
Tape width up to minimum 10 mm requested
Single rewinding of slitted tapes
Requested accuracy +/- 10 m
No delamination of compound (paper, prepreg, film)
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Vertical and horizontal drying technology
concept
Key, performance-determining assembly in whole coating line
variety of product requirements only achievable by different drying concepts
dryer portfolio comprises
air dryers
radiation dryers
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Vertical and horizontal drying technology
Features:
Vertical lifting of upper dryer part on drive and operating side simultaneously (e.g.
easy access when cleaning internal parts of oven), lifting height 450 mm
AC sleeplessly frequency controlled fans for controlling air speed
Inspection windows (double walled) at both sides of dryer
Most accurate temperatures in cross as well as in machine direction (+/-1C)
Lowest shrinkage of material due to very low web tension
Air temperature/fan speed in each dryer section individually adjustable
Remote control of fresh and exhaust air flaps from MMI Proline system
Outside surface temperature of dryer not to exceed 50C
Web temperature access holes provided at end of every dryer zone
All main functions like air speeds, temperatures, web tensions, positions of air flaps
are displayed on MMI Proline system
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Process description
Process control
Radioactive weight measurement
Additional units: Web cleaning with static removal
Resin handling systems
Water chillers, thermo oil heating system + control circuits
Lifting tables and cranes for reel loading and unloading
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Summary
Requested properties on finished product
Information about accuracy (summary of parameters)
Aspired resin content:
- 30 50 %, accuracy +/- 2 %
- variation of coating weight depending of substrate weight
requested accuracy 15 - 50 g/m with +/- 2 g/m,
50 - 150 g/m with +/- 3 g/m
Information for UD quality from aero space industry:
- no gap between single filaments wider than 0,76 mm and longer than 250 mm,
- highest accuracy,
- deep and constant impregnation.
KROENERT GmbH & Co KG
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The Coating Machinery Experts
Summary
Do you have questions?
Thank you for your attention!
KROENERT GmbH & Co KG
