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New production technology development for the continuous production of composite-based LED lightening panels

3 June 2020 News AZL Admin

AZL RWTH develops an integrated process chain for cost-effective and energy-efficient production of electrically and optically functionalized fiber composites in the project “Konfutius” by the European Regional Development Fund (EFRE).

The prices for LED paneling are quite low, so German producers are challenged to compete with the international market. Therefore, the German production process needs new technologies to be able to keep up internationally. AZL and its cooperation partners are taking on the challenge and are currently developing an integrated process chain for cost-effective and energy-efficient production of electrically and optically functionalized fiber composites. This process enables the production of LED panels with cost reductions of more than 60% compared to current LED panels on the international market.

The lighting panels are produced for the first time in a continuous process in a double-belt-press which comprises for example continuous fabrication of TP-FRP sheets, application of functional layers and conductor tracks as well as joining of the layers and crosscutting of the segments. This process even outperforms conventional LED panels in terms of weight and rigidity, while at the same time being less thick and offering greater design freedom.

By transforming the panels into curved structures, which is also aimed for in the project, design-oriented applications in architecture, (e.g. exterior facades), and in the transport sector, (e.g. for ceiling lights in trains and buses), can also be addressed.

Two machine prototypes which are for example being used to produce the support structure of LED panels in this project resulted from a joint partner project and its follow up project that AZL and its partner companies have carried out. The double-belt-press machine and also the ultra-fast machine consolidator are thus just one of various applications that are a great example for our knowingly close collaboration between industry and research and our own technology center with which we are able to develop innovative and competitive processes and productions.

Details of the process design will also be discussed in our Lighweight TechTalk on July 9th which is addressing composites and additive manufacturing. If you are interested to hear more, you can register here for our TechTalk: www.azl-aachen-gmbh.de/termine/lightweight-techtalk-2/

For more information on our services or for support on your project ideas please contact:

Philipp Fröhlig
Senior Project Manager at AZL Aachen GmbH
Phone: +49 241/475735-14
Email: philipp.froehlig@azl-aachen-gmbh.de

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