Diolen®

Enka® Nylon
Enkalon®
Stanylenka®

Enka® TecTape Hybrid Roving

Dr. Stefan Volta, Dr. Christian Vieth, Andreas Flachenecker, Dr. Thomas Roth
Deutsches Fachkolloquium Textil Dresden, 22.3.2018
PHP Fibers GmbH 1
Indorama Ventures

PHP Fibers GmbH 2

PHP Fibers GmbH 3
PHP Fibers GmbH 4
PHP Fibers

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PHP Fibers at a Glance

 PHP Fibers is a globally operating company producing high-tenacity

industrial filament yarns.
More than 700 employees are working in the development, production
and sale of high-tenacity polyester and polyamide filament yarns and their
polymers
 PHP Fibers is one of the leading suppliers of high performance yarns into
the automotive sector: airbags, safety belts, tire reinforcements or belts
and hoses

© Vereshchagin Dmitry - Shutterstock.com (Airbag) / © Ryan Jorgensen-Jorgo - Shutterstock.com (Tire)

 The portfolio of PHP Fibers also includes special types for other
challenging technical areas of application such as roofing and sealing
membranes, textile construction, sail cloth or sewing threads.
 Our brand names Diolen® (PET), Enka® Nylon (PA6.6), Enkalon® (PA6)
and Stanylenka® (PA4.6) are known around the world and are well-
accepted.
 PHP Fibers was acquired by Indorama Ventures (IVL) in 2014

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Requirements for Fiber Reinforced Composites (1)

Construction elements based on

fiber reinforced composites:

 Light weight!
 Suitable mechanical properties (stiffness,
toughness, tenacity etc.)
 Straight alignment of reinforcement fibers
according to applied forces
 Dimensional stability under applied
mechanical and thermal load
 Constant fiber volume content
 Durability in long term application
 Resistance against environmental
influences (chemical attack, corrosion, UV
etc.)

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Requirements for Fiber Reinforced Composites (2)

Reinforcement fibers:
 Mechanical properties: stiffness and tenacity
 Good adhesion to matrix
 Good processability: textile formation and draping

Matrix material:
 Positioning of reinforcement fibers
 Transmissions of tensions (adhesion to
fibers)
 Suitable mechanical, thermal and chemical
properties
 Good impregnation into reinforcement
structures
 Voidless consolidation
 Protection against environmental influences
 Surface appearance / paintability

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Raw Materials for the
Automated Production of Fiber Reinforced Composites (1)

Raw material requirements

 Automated formation of textile structures:

 Weaving
 Braiding
 Winding
 Tailored Fiber Placement

 Drapability: flexible for composite formation

 Short cycle times

 Reproducibility of process

 High output yields; no / low waste

 Joining with other materials and construction

elements

 Process to be integrated in complex

production process lines
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Raw Materials for the
Automated Production of Fiber Reinforced Composites (2)

Solution: hybrid raw materials

 Continuous reinforcement fibers for maximum

stiffness

 Thermoplastic matrix material on fiber basis for

short cycle times

 Defined fiber volume content

 Good drapability

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Raw Materials for the
Automated Production of Fiber Reinforced Composites (3)

Challenges
 Orientation of reinforcement fibers

 Constant fiber volume content

 Constant dimensions in width and thickness

 Compactness: no trapped air and low

volume raw material

 High viscous thermoplastic matrix

 Impregnation
 Consolidation
 Shrinkage

 Even distribution of reinforcement fibers to

matrix fibers

 Surface / Filamentation

 Reproducibility of process
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Our Solution:
Enka® TecTape Hybrid Roving

 High reinforcement fiber orientation

 High compactness

 Constant width and thickness

 Constant fiber volume content

 Smooth surface i.e. low friction

 Flexible for textile formation

 Short melt flow distances

 High melt flow polymer
 Low shrinkage

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Competition
Enka® TecTape Hybrid Roving vs. commingled yarn

Enka® TecTape parallel hybrid rovings: Commingled yarns:

 Parallel alignment of reinforcement and  Reduced degree of fiber orientation

matrix fibers  Irregular distribution of reinforcement and
 Constant fiber volume content thermoplastic fibers
 Smooth roving surface  Rough Surface / Filamentation

Fabric from Fabric from

1800 tex- GF-PA 1800 tex parallel hybrid roving 1800 tex - commingled yarn, Source ITV Denkendorf

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Enka® TecTape Hybrid Roving
Technical Data

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Enka® TecTape Hybrid Roving
Samples from processing (1)

thoenes Dichtungstechnik GmbH / Institut für Leichtbau und Kunststofftechnik der TU Dresden
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Enka® TecTape Hybrid Roving
Samples from processing (2)

TITK, Rudolstadt
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Enka® TecTape Hybrid Roving
Samples from processing (3)

TITK, Rudolstadt
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Enka® TecTape Hybrid Roving
Samples from processing (4)

Delcotex Delius GmbH & Co. KG, Bielefeld

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Hy:Ro Bike
PHP Fibers Bicycle Project
2017

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Hy:Ro Bike Project 2017:
6 Steps from Enka® TecTape to High-Tech Composite Bicycle

PHP Fibers GmbH

01 Hybrid Roving Production

Rehau
02 Composite Tube Design and Simulation

Siltex
03 Hose Braiding

Rehau
04 Composite Tube Manufacturing

Mi:Tech
05 Frame Manufacturing

Mi:Tech & Continental

06 Bicycle Manufacturing

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Enka® TecTape Hybrid Roving Production

01

• Production of Hybrid Rovings

combining twist free aligned
continuous glass fibers with
thermoplastic multifilaments
• The raw material for the automated
production of textile based fiber
reinforced composites

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Composite Tube Design and Simulation

02a
Steel pipe Composite pipe

Modelling and simulation of

thermoplastic fiber reinforced
composites (TFRC) for the
alternative bicycle frame

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Composite Tube Design and Simulation

• „Riding out-of saddle“ simulation

round steel pipes vs. composite based frame
02b

• „Torsion rigidity“ simulation

round steel pipes vs. composite based frame
Modelling and simulation of
thermoplastic fiber reinforced
composites (TFRC) for the
alternative bicycle frame

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Composite Tube Design and Simulation

02c

Relative
Frame
weight

Steel 100% Modelling and simulation of

thermoplastic fiber reinforced
Composite - Steel 92%
composites (TFRC) for the
Composite - Aluminium 84%
alternative bicycle frame

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Hose Braiding

Braiding of triax hose structures

with Enka® TecTape Hybrid
Roving in natural white and
black color according to design
requirements of Rehau

03

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Composite Tube Manufacturing

• Design of impregnation and

consolidation tools
• Manufacture of thermoplastic
fiber reinforced composites
(TFRC)

04

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Frame Manufacturing

05

• Design and manufacturing of

aluminum frame components
• Assembly of bicycle frame

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Bicycle Assembly of the Hy:Ro Bike

06
Hy:Ro Bike

Bicycle assembly with further

fiber reinforced components:
- Belt drive system from ContiTech
- Bicycle tires from Continental
Source: Schendel und Pawlaczyk Messebau

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Thank you for your attention!

Source: Schendel und Pawlaczyk Messebau

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