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Composite Materials for the Future

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Moving beyond simply providing strength, lightness, and stiffness as in the past to delivering new capabilities, we aim to generate higher added value and greater satisfaction for customers by offering an array of elegant design solutions, manufacturing technologies, and new ideas for composites.

CFRPs   Torque transmission shafts   Precision rods  

CFRPs

Too expensive to use as replacements for existing products?

CFRPs boast unique properties that only composites and anisotropic materials can offer.

Taking this point into account, we aim to develop with our customers the ultimate products that go beyond simply replacing existing parts.

Fujikura Rubber Ltd. – the experts in P-QCD mass production

“Performance-based QCD” is our watchword.

FUJIKURA COMPOSITES are experts in the manufacture of mass-produced parts, and are committed to achieving the ultimate in performance while satisfying customers’ quality, price, and turnaround requirements.

  CFRP
 
 

Technological capabilities

Design
The expertise gained from years of experience in developing and manufacturing rubber parts and golf club shafts
The simultaneous multilayer winding method can maximize strength development rates for minimized consumption of materials
Development of products that leverage the properties of cylindrical geometry
Full use of all kinds of fibers and woven materials
Numerical analysis (structural and flow analyses, etc.) and testing and evaluation capabilities (extensive physical and chemical testing facilities)
 
Processing
Stable performance and quality, minimization of costs
High dimensional accuracy, creation of surface functions (plating, high-precision assembly, machining)
 
Compositing
Creation of composites from rubbers, resins, and metals applying varied joining and bonding technologies
 
 

Advantages of CFRP cylinder products

 

Fujikura Composite’s proprietary strength-improving lamination technique

Simultaneous multilayer winding*
 
By analyzing the winding structures produced by sheet winding, we have succeeded in developing a laminated structure that is less prone to delamination, which is a shortcoming of cylindrical CFRP products, and mitigates damage such as fiber buckling inside cylindrical materials.

The optimal lamination to meet strength, stiffness, and other requirements is identified through a combination of computation and empirical knowledge to minimize usage of material.

 
*International Publication No. WO2010/084809 A1
  Advantages of CFRP cylinder products
 
■Process for precision molding inside and outside diameters
 
In addition to grinding the outside diameter, the inside diameter is precisely molded by a sheet winding process that involves winding prepreg around a mandrel.
Compared with hollow steel pipes, CFRP pipes with extremely precise inside and outside diameters have much better torsion buckling limits.
  Advantages of CFRP cylinder products
 
■High lamination flexibility
 

Cylindrical CFRPs are not vulnerable to warping and so require none of the symmetric lamination normally fundamental to plate materials. This yields much greater lamination flexibility and allows EI and GIp to be freely tuned within the same cylinder.

As surplus lamination can be eliminated, products can also be precisely designed using the minimum amount of material.
  Advantages of CFRP cylinder products
 
 

Typical products: Golf club shafts - the composite material product par excellence

 
For the golfer seeking the ultimate in ball control
 

Superb ball handling, ideal trajectory to the target, more precision over maximal distance using a wood, and super precision with an iron – we make the shafts to make this golfing dream a reality.

The shaft of a club is like an extension of the body through which the player communicates with the ball.

Our approach to fitting is that “one hundred different players need one hundred different shafts.”

Each golfer has his or her own unique swing pattern.

We have optimized EI distribution for swing (low, middle, and high kick point).
 
■Highly flexible stiffness tuning
 

Taking full advantage of the benefits of anisotropic laminates, EI and GIp can be freely designed by adopting the desired laminate configuration according to position on the shaft.

  Advantages of CFRP cylinder products
 
Curvature frequency curve
 
Lamination pattern
 
 
 

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Torque transmission shafts

■High-precision sheet winding

We have developed a manufacturing process and manufacturing equipment* that minimize fiber distortion and voids in laminates, resulting in improved performance and more stable quality.

*Patent No. 4859975
   High-precision sheet winding
■Internal observation with ultrasonic flaw detector
Our proprietary technology (simultaneous multilayer winding)
 
Conventional technology (ordinary winding)
   
 
   

High strength

Maximal use of properties of materials 20% improvement over conventional technology
 
High strength
Improved strength due to simultaneous multilayer winding
 

High stiffness

Fibers having all kinds of elastic modulus can be used
 
High stiffness
Numerical analysis of torsional buckling Assisted by ESI Japan Ltd.
 

High design quality

Manufacturing backed by outstanding numerical analysis techniques, experimentation, and prototyping expertise
 
High design quality
Fuse point
*Special joint structure
*International Publication No. W02011/024527 A1
 

Dependable quality

Variety of joining methods to choose from according to application
 
Dependable quality
Strength evaluation of joint sections
 

Lower weight

Drastically lighter thanks to use of carbon for key parts
 
Lower weight
Weight-reducing effect relative to design length of carbon shafts by target torque (compared with iron shafts)
 

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Super-light precision CFRP rods

■Issues with CFRP rods as metal replacements
・As resin is exposed on the surface, hardness is low and machining precision is poor.
・Compared with metal, CFRPs are less resistant to oil and chemicals.
 
■Research by Fujikura Rubber to solve these issues
Plating of CFRP surfaces
→Higher surface hardness
→Micron-level precision on a par with metals (straightness, coaxiality)
→Resin processing tolerance: ±0.05 => Plated CFRP rod processing tolerance: max. ±0.005 
→Usable for precision instruments
→Improved oil and chemical resistance
 
 
Connection with metal fittings
→Metal fittings can be used to avoid the difficulties with screwing and drilling associated with CFRPs
→High-precision small-scale machining possible using main spindle moving lathe
→Highly dependable joints due to use of proprietary technology
 
 

Lighter

Steel (490 g)   CFRP (230 g)   Aluminum (970 g)   CFRP (420 g)
Steel (490 g)   CFRP (230 g)   Aluminum (970 g)   CFRP (420 g)
   

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