Tailored Materials

New high-performance polymers are the basis for fiber-plastic composites and complex fiber composite components. The synthesis of the polymers and formulation of the reactive resins represent the beginning of the development and value chain. In the next step, the polymers are used to manufacture semi-finished products and high-performance prepregs with a wide variety of fibers. Microwaves or UV light are used for energy-efficient processing of the polymers. In addition to these focal points, concepts, processes and technologies are developed for the repair and recycling of fiber-reinforced components.

Services

• alternative curing methods (UV, microwave, IR, e-beam)
• recycling and Repair
• high Performance Polymers
• microelectronics, photonics (function integration)
• SMC, BMC
• biobased thermosets
• natural fiber reinforced plastics
• biofunctional surfaces (function integration)
• prepregs
• fire protection systems

Equipment

• reactors up to 20 L
• mixing technology
  
• cryogenic mill and vibrating mill
• glovebox
• clean room with wet workstation complementary for processing of thin films, optical polymers
• surface treatment by corona and low pressure plasma
• UV-LED curing (up to 800 mm width)
• microwave technology
• spray drying
• optical m-line measuring station (refractive index, birefringence, layer density, attenuation, thermo-optical coefficient)
• dielectric broadband spectroscopy
• µHz - 3GHz (-150 to 400° C)
• horizontal impregnation and coating line (40 to 800 mm width)
  • coil unwinding and fiber spreading module for UD high performance prepregs
  • various impregnation and coating modules
  • divisible for multilayer systems and functional prepregs
  • mono- and multi-mode microwave modules
• vertical impregnation system
• discontinuous microwave oven (8 m³)
• kneader: up to 2.5 L chamber volume, up to 200 °C, 0 to 3 bar absolute
• three-roll mill with temperature-controlled (10 - 70 °C) SiC rolls, nip or force control

Polymer development

At the beginning of the development and value chain of the research area is the polymer development working group. The synthesis and formulation of new (reactive) polymer materials as matrix resins for fiber composites but also for applications in microelectronics and photonics are the focus here. Achieving application-specific property profiles with frequently opposing parameters is a major challenge here. One focus of activities is on the development of damage-tolerant, flame-resistant and thermostable duromers, with increasing importance being attached to the sustainability aspect in the form of renewable raw materials and polymers suitable for recycling and repair. Profound expertise in the field of energy-efficient curing processes (IR, microwave, UV and e-beam) and the duromers adapted to these processes round off the profile of the working group.

Contact: Prof. Dr. Christian Dreyer

Semi-finished components

At the interface between material development and production, the working group develops new and customized semi-finished products for polymer-based lightweight systems, from individual components to large-scale production. The focus here is on the production of prepregs on scalable production lines as well as the development and process engineering evaluation of core materials and molding compounds such as sheet and bulk molding compounds (SMC/BMC). Renewable raw materials and energy-efficient processes play a central role here. This also includes the specific equipment of the polymer semi-finished products with regard to mechanical material performance and further functionalization, such as fire resistance and antimicrobial component surfaces.

Contact: Dr. Mathias Köhler