Schappe Techniques Proprietary and

Confidential
1
Plant :
Rue dAlsace
F - 88 520 La Croix-aux- Mines
Tl: +33 (0)3 29 52 23 23
Fax: +33 (0)3 29 51 79 10


Administration & Sales Dpt :

Parc Ind. de la Plaine de lAin
Alle des Erables
F 01150 Blyes
Tl: +33 (0)4 74 46 31 00
Fax: +33 (0)4 74 34 79 35

Spinning company

Sales 2012: 13 M
- to France : 27 % of the sales
- to Europe : 46 % of the sales
- to ROW : 27 % of the sales
350 Tons of yarns/year
ISO 9001/2008 Certified
Schappe Techniques
138 employees
Schappe Techniques Proprietary and
Confidential
2
Schappe Techniques position in the textile chain
Fibre producer
Weaver Knitter Braider
Intermediate product
manufacturers
(Composites for example)
Garment
Maker
woven fabrics
knitted fabrics
braids
Garment makers, final product
Manufacturers (conveyor belts,
joint packings etc...)
fibres
spun yarns
Finished product manufacturers
(Automotive for example)
Final market
finished
products
finished
products
intermediate products
finished products
Spinner
(Schappe Techniques)
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Schappe Techniques processes
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Schappe Techniques general processes
Stretch breaking Pin drafting Spinning Winding Twisting Control
Continuous filament
raw material
Yarn
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Specific processes to Stretch Broken fibers
Standard spinning processes
The stretch breaking process


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Stretch breaking consists of transforming the continuous
filaments into a top of long fibers.
Originally, this technique allowed to remove the weak
points of the fibers and to improve their characteristics by
increasing their tenacity and spinability.
The stretch breaking process
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Fiber length diagram:
Typical lengths for carbon fibers:
Maximum length: 200-220 mm
Average length: 65-70 mm
Minimum length: 35-40 mm
Key Features of Stretch Broken Yarns

Versus continuous filaments:

Intimate blends for tailored properties (ie: composites)
Cost competitive: Fine yarns made of heavy tows
Larger metric count range
Comfort and softness
Higher bulk
Lower tensile strength

Versus short staple yarns:

Higher tensile strength
Higher abrasion resistance
Higher Metric count limit : thinner yarns
High flexibility for small productions (trials, sampling)
Cleaner yarns (evenness, regularity)



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Sales segmentation
Individual protection
Technical sewing threads
Fire blocking
Packing
Reinforcement
Antistatic
Glass industry
Composites
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Different types of yarns made by Schappe Techniques
Single: Yarn is twisted
Plyed yarn: Individual yarns are twisted and then plyed together
with opposite torsion
Plyed with steel: Steel(Inconel) yarn is inserted between the yarns
during the plying operation
Wrapped: Core is made of parallel or twisted filaments,
wrapping yarn is offering mechanical protection
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Schappe Techniques products for Composites
Thermoplastic prepregs: TPFL

Carbon/Carbon precursors

Thermoset reinforcements

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Schappe Techniques products for Composites
Thermoplastic prepregs: TPFL

Carbon/Carbon precursors

Thermoset reinforcements

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A drapable prepreg which can be consolidated in a
short time for the production of high performances parts.

The goal
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Detail of a TPFL

yarn
Reinf. Fibre +
Matrix fibre
Matrix fibre
TPFL

fabric
TPFL

yarn
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The TPFL

intimate blend (Before consolidation)
Polymer Fiber
(PA12, 50m)
Reinforcement Fiber
(Carbon, 7 m)
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Air
Twintex - The Commingling Concept
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TPFL Yarn
Prepreg
Consolidated
Composite
Temperature
+ Pressure
The TPFL

intimate blend
TPFL

processing cycle (PEEK Temperatures)

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The TPFL

portfolio
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Reinforcement fiber









The TPFL

range


Intime blend
Matrix fiber
Sliver
Yarn
UD Sliver Preconsolidated UD UD Laminates
Braids
Multiaxial
Pellets
UD Fabrics 2D
Fabrics
Preconsolidated
fabrics
Flakes
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TPFL

combinations
Carbon
S2-Glass
Ceramics (Nextel, SiC)
Para-Aramide
Linen (Flax)
PA 12, PP
PPS
PEEK
Reinforcement
Fibers
Matrix
LCP
PBT, PET
PEI
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What are the raw material selection limitations?
For Reinforcement Fibers
Fiber sizing shall allow the fibers to slip during stretch breaking operations,
but shall not be degraded during processing (temperature) and shall allow
decent interface between matrix and fiber. Consequently: No E-Glass in our
range

For Polymer
Polymer shall be available as a fiber, continuous or long enough to be carded

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Typical properties of carbon fibers used by Schappe Techniques
Fiber Elongation Density Certified for
Aerospace
4000 Mpa 240 Gpa
580 ksi 34,8 Msi
4278 Mpa 228 Gpa
620 ksi 33,1 Msi
5570 Mpa 276 Gpa
808 ksi 40 Msi
Hexcel AS4 1,87% 1,79 gr/cm3 Yes
Hexcel IM7 1,90% 1,78 gr/cm3 Yes
Tensile Strength Tensile Modulus
Toho-Tenax STS40 >1,6% 1,76-1,82 gr/cm3 No
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Temperature
(C)
Polymer service temperatures
Tg
Tm
Ts
Polymers
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Polymer processing temperatures
Temperature
(C)
Tg
Tm
Tp
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New TPFL yarns and reinforcements proposed by Schappe
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Style Polymer Fiber
98644 PA12 S2 Glass
98645 PEEK S2 Glass
98705 PA12 Linen
98821 PEI Carbon
98799 PA12 Linen
98800 PA12 Linen
Style Polymer Warp Yarn Weft Yarn Construction Weaving
Pattern
Total Aerial
Weight
Fiber Aerial
Weight
Fiber
Weight
Fraction
Fiber
Volume
Fraction
Composite
Density
90153P PA12 3,8 x 3,8 2/2 Twill 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3
90154P PA12 3,8 x 3,8 4/4 Twill 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3
90155P PA12 3,8 x 3,8 Plain 380 Gr/m 5% 243 Gr/m 5% 64% 3% 57% 3% 1,22 Gr/cm3
90173P PA12 98799 Nm 3,7 Linen/PA12 54/46 98800 Nm 7,4 Linen/PA12 54/46 3,8 x 3,8 2/2 Twill 351 Gr/m 5% 190 Gr/m 5% 54% 3% 40% 3% 1,31 Gr/cm3
90174P PA12 98799 Nm 3,7 Linen/PA12 54/46 98800 Nm 7,4 Linen/PA12 54/46 3,8 x 3,8 Plain 351 Gr/m 5% 190 Gr/m 5% 54% 3% 40% 3% 1,31 Gr/cm3
Style Polymer Warp Yarn Weft Yarn Construction Weaving
Pattern
Total Aerial
Weight
Fiber Aerial
Weight
Fiber
Weight
Fraction
Fiber
Volume
Fraction
Composite
Density
90156P PEEK 5 x 5 Plain 313 Gr/m 5% 188 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3
90157P PEEK 5 x 5 2/2 Twill 313 Gr/m 5% 188 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3
90160P PEEK 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 52% 3% 1,55 Gr/cm3
90161P PEEK 40501 Nm 3,2 Carbon/PEEK 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 62% 3% 53% 3% 1,57 Gr/cm3
90163P PPS 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 54% 3% 1,58 Gr/cm3
90166P PPS 51804 Nm 3,2 Carbon/PPS 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 61% 3% 54% 3% 1,61 Gr/cm3
90178P PEI 7,5 x 7,5 5 HS 469 Gr/m 5% 281 Gr/m 5% 60% 3% 52% 3% 1,53 Gr/cm3
90179P PEI 98821 Nm 3,2 Carbon/PEI 60/40 EC9 34 tex Glass 8,5 x 3 UD Plain 276 Gr/m 5% 170 Gr/m 5% 61% 3% 52% 3% 1,55 Gr/cm3
98705 Nm 2 Linen/PA12 64/36
New High Performances Fabrics
40501 Nm 3,2 Carbon/PEEK 60/40
New Yarns
Fiber Weight Fraction Fiber Volume Fraction Metric Count
40% 3% 7,4
72% 3% 52% 3% 2,4
67% 3%
98821 Nm 3,2 Carbon/PEI 60/40
60% 3% 52% 3% 3,2
54% 3% 40% 3% 3,7
54% 3%
40501 Nm 3,2 Carbon/PEEK 60/40
40501 Nm 3,2 Carbon/PEEK 60/40
51804 Nm 3,2 Carbon/PPS 60/40
New Natural Fibers Fabrics
98705 Nm 2 Linen/PA12 64/36
98705 Nm 2 Linen/PA12 64/36
52% 3% 2,2
64% 3% 57% 3% 2
Flax-PA12 applications

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27
Flax-PA12 applications

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Consolidation techniques



1. Most used
Cold stamping
Diaphragm forming
Bladder Inflation Moulding (BIM)
Compression Molding
Autoclave
2. Emerging processes (RocTool)
Inductive heating

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29
The stamping process
Pre-heating Preform placement
(Tp > Tm)
Stamping Demoulding
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The cold stamping process



Techniques that is widely used for consolidated thermoplastics, allowing fast
processing
When using TPFL materials that are not consolidated, consolidation requires:
Pre-heating of the material to processing temperature, typically Tf + 30C
Time to allow the polymer to flow and wet-out the fiber
Cooling down the material until the T< Tg
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The stamping process
Sump, EMS Chemie - TPFL carbon/PA12
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The stamping process (Silicone tool)
Vido : TPFL_fabric.avi
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The diaphragm forming process
membrane
TPFL

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Silicone membrane
The diaphragm forming process
Gusset,EMS Chemie - TPFL carbon/PA12
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Key feature of TPFL materials
Fibers are slipping during the process
Yarns are elongating (Up to 20%)
Absence of wrinkles in the edges

The bladder inflation moulding process
Use of TPFL braids
Easy lay-up
No joints, no overlap
Possibility of evolutive sections, curved parts

TPFL
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The bladder inflation moulding process
Vido : TPFL_braid.avi
Real applications : Sporting goods with
Carbon/PA12 TPFL braids. Typical cure
cycle: >5, 10 bars, T = Tf +30 C





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Compression molding and injection
Compression molding is already used with TPFL
pellets


Development and characterization of TPFL
flakes is ongoing. Goal is to make HP composites
with injection

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Fast processing technique : Induction heating
3iTech tube video.mov

Use of induction heating system developed by
allows the use of silicone that are theoretically nor
capable to withstand such processing temperatures.
Reason is due to short thermal history of the silicone

Schappe Techniques Proprietary and
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TPFL

mechanical properties (UD)
Tensile Flexural

(MPa)
E (Gpa)
(MPa)
E (Gpa)
Vf %
CF/PA12
CF/PBT
CF/PPS
CF/LCP
CF/Peek
-
1850
1400
1800
1080
123
85
120
-
98
1435
750
1650
1200
1010
100
92
101
105
107
53
53
53
53
53
Results obtained on UD at room temperature
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Please discard mechanical properties claimed for fabrics in TPFL brochure
The TPFL

solution
Short cycle moulding
High Mechanical Properties
High drapability: Very suitable for complex shapes and hollow parts
Very low void content (<0,2 %)
Environmental friendly
Low cost solution
Recycling
Schappe Techniques Proprietary and
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45
Schappe Techniques products for Composites
Thermoplastic prepregs: TPFL

Carbon/Carbon precursors

Thermoset reinforcements

Schappe Techniques Proprietary and
Confidential
46

Different types of yarns made by Schappe Techniques
Single: Yarn is twisted
Plyed yarn: Individual yarns are twisted and then plyed together
with opposite torsion
Plyed with steel: Steel(Inconel) yarn is inserted between the yarns
during the plying operation
Wrapped: Core is made of parallel or twisted filaments,
wrapping yarn is offering mechanical protection
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47
Multiaxial textures
Carbon/Carbon precursors
UD Carbon
Carbon yarns
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Carbon/Carbon applications
Carbon Clutch pads
Rods and screws
Oven soles
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Schappe Techniques products for Composites
Thermoplastic prepregs: TPFL

Carbon/Carbon precursors

Thermoset reinforcements

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50
Thermoset reinforcement applications
Truck clutch pads
Industrial friction parts
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Carbon Sewing Threads

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Carbon thread 1K x 2
1. Developed by Toho-Tenax
2. Produced by Schappe Techniques
3. Nowadays marketed and produced by Schappe
Carbon Sewing Threads

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First flying application : B787 Main Landing Gear Brace (Messier-Dowty)
Carbon Sewing Threads

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Composite Door Demonstrator (Latcore)
Carbon thread 1K x 4