Carbon Fiber What’s in the Windwindpower.sandia.gov/2004BladeWorkshop/PDFs/TomLemire.pdf · Carbon Fiber What’s in the Wind ? February, 2004 ... What is Carbon Fiber How is it

Carbon Fiber

What’s in the Wind ?February, 2004

Wind Turbine Blade Workshopin Albuquerque, NM

Presented byToho Carbon Fibers Inc.

Tom LemireH. Jin Onodera

Toho Tenax Co., Ltd., Toho Carbon Fibers, Inc.Tenax Fibers, GmbH

Table of Contents

What is Carbon FiberHow is it Made

Where the industry Came FromWho is Toho

Carbon Fiber Production CapacityWhat is the Demand Growth

How is Carbon Fiber Supplied

Why Carbon FibersC/F Performance RangeTypical Fiber Properties

Where is it Used TodayWind Energy – EuropeComposite Mechanical Properties


What is Carbon FiberWhat is Carbon FiberHow is it Made

Precursor Oxidization Carbonization

Surface Treatment Sizing Winding


Where We Came FromPAN based Carbon Fiber Manufacturers

Earlier Suppliers 2004 Suppliers

Toray (Soficar) Toray

Toho Rayon (Tenax) Toho TenaxBASF

Celanese Union Carbide BP Amoco Cytec Carbon Fibers

Hercules Hexcel

Courtaul Hysol Grafil MitsubishiAsahi

Great Lakes Fortafil Accordis

Stackpole Zoltek

RK Carbon SGLAldila Carbon Fiber Technologies

Formosa Plastics


Who is Toho ?Who is Toho ?

Asia TOHO TENAX

• Production Sites

• R&D, Test Laboratory

• Sales Offices

North AmericaTOHO CARBON FIBERS

• Sales Offices

EuropeTENAX FIBERS

• Production Site

• Test Laboratory

• Sales Office

TOHO TENAX Group is Global Player

in the Carbon Fiber Market.


18%

23%15%

6%

6%5%

TohoTorayMitsubishiHexcelCytecF.P.C.Heavy Tow

Carbon Fiber Production Capacity

• Total Capacity: 31,800 ton per Year

Toho Tenax Group has 5600ton per year, second largest capacity.

11% 7% 6% 3%


Demand Growth of Carbon FiberDemand Growth of Carbon Fiber

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

Ton

per Y

ear

'01 '02 '03 '04 '05

IndustrialRecreatioanalAerospace


How is Carbon Fiber SuppliedConventional Tows

Standard Modulus 34 MSI3K, 6K, 12K, 24K

Intermediate Modulus 40 MSI6K, 12K, 24K

High Modulus 50 MSI6K, 12K, 24K

Large TowsStandard Modulus 34 MSI

45K, 48K, 80K

Fabric, Dry Tapes, Assembled Preforms,

Unidirectional Prepreg Tapes, Prepreg Tow,

Continuous Pultrusions, Filament Wound Parts, etc.


Why Carbon Fiber ?

Able to Make Light Weight Parts

High Performance(Strength, Modulus)

10


0

100

200

300

400

500

600

700

800

900

0 10 20 30 40 50 60 70 80 90Tensile Modulus [MSI]

Tens

ile S

tren

gth

[KSI

]

CF / Performance Range

E-Glass

Twaron

Steel

G30-500

G40-800

G50-300

G55-700 G60-600

G80-600

G30-700

　Carbon Fiber (BESFIGHT®)　Glass Fiber　Aramid Fiber (Twaron)　Steel

　Carbon Fiber (BESFIGHT®)　Glass Fiber　Aramid Fiber (Twaron)　Steel

STS 24K

Fiber Test Method: Based on JIS R7601


Fiber PropertiesBesfight STS 24K F301

1.6 g/mYield

1.75 g/ccDensity

34.6 MSITensile Modulus

570 KSITensile Strength

1.7%Elongation

Typical data


Where is Carbon Fiber Used ?

Wind Turbines of 2 –5 MW Capacity

Composite Blade of Greater than 35 m length


0

500

1000

1500

2000

2500

3000

3500

4000

2001 2002 2003 2004 2005

Ton

per Y

ear

Demand Forecast

Carbon Fiber Usage for Wind Blade


Composite Mechanical Properties

Carbon Fiber: STS 24K F301 (STS 5631 1600tex f2400 t0)Resin Matrix: 120 ℃ cure Epoxy Resin System

0.71070915055Stitched0゜/90゜

1.0151401825055Woven

0゜/90゜1.0990915055 – 60Bonded

1.0990915055 – 60Stitched

1.0151501726055 – 60Woven

0.9

0.9

0.9

1.2

1.4

Elongation [%]

15

15

15

17

22

Modulus [MSI]Strength [KSI]

1301731055 – 60Bonded

1301731055 – 60Stitched

18

22

25

Modulus [MSI]Strength [KSI]

150

200

270

Max. Value Compression 0゜

290

340

380

Max. value Tensile 0゜

55

60

65-70

Max. Vf.

Stitched

None

None

FiberFixture

0゜

0゜

0゜

FiberDirection

RTM

Prepreg(Also Semipreg and RFI)

Pultrusion

ManufacturingProcess

Tested by Tenax Fibers


Wind Energy - EuropeManufacturing Technologies

LM, DeWind, A&RDevold,BTI, Saertex

Vacuum resinInfusion moulding

LM - tip shaftsNEG – tip shafts

LM GlasfiberCompoTech/CZ

Filament winding

Abeking & R.ATV / Euros

Tow wet lay-up

NEG Micon Rotors(Aero Laminates)

Fibre Force/UKExcel/FINEpsilon/FR

Pultrusion

VestasVestasNordex, DeWind

HexcelSP SystemEPO

Semipreg

Power Station Manufacturer/Blade Manufacturer

SupplierProcess

Documents

Carbon Fiber What’s in the Windwindpower.sandia.gov/2004BladeWorkshop/PDFs/TomLemire.pdf · Carbon Fiber What’s in the Wind ? February, 2004 ... What is Carbon Fiber How is it