The company Pel-Job (Annecy-le-Vieux, France), a subsidiary of the Swedish group Volvo, is using DCPD (dicyclopentadiene) "Telene" from BF Goodrich and Cray Valley (group Total) for the fabrication of body parts and structural parts on its latest range of mini-excavators. The new models of Pel-Job – EB 150 and EB 200 – include four parts made with "Telene": the rear hood, the rear hood base, the floor and the trap door. "The choice of Telene results from a unique combination of properties that cannot be obtained with traditional materials", explained Didier Lavigne, product manager of Pel-Job on the occasion of an European press trip. With a density of about 1 g/ccm, "Telene" is much lighter than steel. It has a high impact resistance from -40 °C to 110 °C and is very easy to paint (no surface treatment) which means it can be used for the production of class A body parts for automobiles. Compared with polyester resins (BMC/SMC), "Telene" requires a lower initial investment as the moulds are made in aluminium instead of steel. "For any given part, a RIM PCDF mould is 1/5 to 1/10 of the cost of a thermoset mould", claims Gerard Mongin, general manager of Telenor SA (PO Box 22, F-62320 Drocourt), the distributor of "Telene" in Europe.

The liquid resin is injected at low pressure (3 bar) into the closed mould, preheated between 65 and 85 °C. For a standard part (weight 5 kg, thickness 5 mm), the average cycle time is between 120 and 150 s. "On the other hand, the largest part moulded to date with "Telene" weighs around 300 kg, injected over 8 minutes with a cycle time of under 45 minutes", added Pascale Benoit de Coignac, development manager at Telenor.

The moulds and the parts for Pel-Job are produced by the plastic processor Courbis Synthese SA (PO Box 251, F-26106 Romans). The company has invested FFR 7m (USD 1,2m) to create a new injection unit, entirely dedicated to the production of RIM "Telene". This new department called "Courbis Mastershock" is equipped with 3 mixers from Cannon (40 to 100 kg/min), 5 presses, 1 paint shop and a sanding shop. "We are able to produce parts measuring up to 3x2 meters, for series ranging from 500 to 10.000 parts per year", explained CEO Daniel Courbis. With 12 employees, Courbis Mastershock transforms 20 t of "Telene" per month for very demanding markets such as the agro-food market and construction.

Telenor SA is a 50/50 joint-venture between Cray Valley and BF Goodrich (Cleveland, Ohio, USA). This jv was created in 1989 and started commercial activities in 1993. "Telene" is currently manufactured in Japan and USA, but Telenor will very shortly have a production site in Europe. In 1997, the market of "Telene" is estimated at 1000 t/y in Europe, 4000 t/y in the USA and 10,000 t/y in Asia/Japan.

READER SERVICE: Brochure (English) "Liquid DCPD RIM Resins": PIE-No. 39355 – Company Profile Courbis (English): PIE-No. 41899.