Source: Sabic KraussMaffei Fiber Composites Technologies

Source: Sabic

KraussMaffei Fiber Composites Technologies Polyurethane applications

9 de Noviembre 2011 – Buenos Aires

Manuel Weindl

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Relation of weight and performance

3

KraussMaffei process technologies for composites

the need for composites – development of weight

0 200 400 600 800 1000 1200 1400

VW Golf

Opel Kadet /Astra

Ford Escort /Focus

Renault 19 / Megane

1974 2006

kg

4


The need for composites

Reason for increased weight

- Airbag systems

- crash protection

- reinforcements for side-, rear-, and front impact

More comfort and luxury

- Servo engines

- Sensor technology (park distance)

- Navigation and communication systems

- Increase engine power

- Car size /Comfort size

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e-Mobility in Germany

up to 3 Mio cars expected in 2016

Sanyo (Japan)

Accumotive(D), Cobasys(US)

Continental (D) Johnson Controls (US)

Tesla(US), MesDea (Schweiz),

BYD (China)

SB LiMotive (D/Korea)

AC Propulsion(US)

Continental(D)

BYD (China),

Sanyo (Japan),

Toshiba(Japan),

Varta (D)

Cooperation

2010

2012

2010

2013

2013

2013

2013

2013

Availability

E-tron

Smart Fortwo ed

A-class E-cell

SLS AMG

Megacity Vehicle

(MCV)

E-Up

Golf Blue-e-motion

Jetta Blue-e-motion

Model

Audi

Daimler

BMW

VW

Benefits – Possibilites – Expectations – Network – Process Equipment

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A single-vendor supplier

• LFI – Long Fiber Injection Moulding

• Honey comb technology

• FCS – Fiber Composite Spraying

• SCS – Structural Composite Spraying

• RTM – Resin Transfer Moulding

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LFI – Processing Unit

Working Principle

Fiber / PU Mixing Area

Fiber Supply

PU Mixing Area

Cutting device

Roving Feeding

Component supply

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2.

• High stiffness

• Locally adjustable fiber

content

• Locally adjustable fiber

length

• small thermal warpage

A unbeatable combination of different characteristics

LFI (Long Fibre Injection) – Main Advantages

2.

outstanding

Part properties

3.

Flexible

Production

1.

cost

Advantages

3.

• Flexible color management

• no pre-forming necessary

• No manual glass handling

• One step process

• Integration of inserts/fixing

elements possible

1.

• Use of cost effective base material

(Glasrovings instead of matts).

• Minimum Waste

• No thermoforming equipment

LFI

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Bildbereich

Production line at Company Fritzmeier

Flexible solution for production up to 40 different

D:/Präsentationen/LFI/Shuttle/LFI_01_06.mpg

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Roof module VW Scirocco und Mercedes R und M MCC Roadster

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Application example of LFI:

• Opel Zafira

• PU GF22 frame with GEP Lexan SLX plastic film, 8300 g

Innovation:

• Perfect wetting and distribution of the glass fibres

• Fibre length and volume locally adjusted, no fibre orientation

• Suitable for large body panels

Benefit:

• High dimensional stability structure and accurate fit

• Direct foil lamination in a single working process

• Less process steps (integration of xxx lines possible)

Application references

Automotive

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• Smart

• PU GF15 frame with 2xPMMA and ASA/PC plastic film, 6000 g

Innovation:

• Inetrgration of fixing elements



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Fendt Roof Module

Fa.-Fritzmeier Composite

Size: 1760*1630*235 mm

Wall thickness: 4 – 10 mm

Area: 3,1 m²

Foil: 2% PMMA clear

13% PMMA white

85% ABS white

total tickness 1,5 mm

Weight PUR: 10,5 kg

Weight GF: 3,5 kg ( 25% )

Injection time: 22 s

Reaction time: 7 min.

D:/Präsentationen/TechDay Shnaghai/RAM 113 LFI-Doppel-Shuttle-Anlage.wmv

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• Front Grill

• PU GF25 frame with plastic film,

Innovation:




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• BMW 6er convertible

• PU GF covered with aliphatic PU system

Innovation:



• Exterior body part over molded with aliphatic PU system

D:/Präsentationen/LFI/LFI Shuttle_Rohschnitt_04_12_07.wmv

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Tractor engine hood New-Holland

Coextrudierte Folie

0.75 - 1.5 mm

(2xPMMA und ASA/PC)

PUR/GF 3.7 - 8 mm

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Applications

Automotive

Application:

• Different exterior parts

• PUR LFI with in mold painting

Innovation:

• Barrier coat processing technology RIM STAR and PEGASUS

• LFI processing technology RIM STAR and LFI mixing head

• System engineering and mold know-how

Benefit:

• “High surface quality” produce with reduced resources and energy …

• One step process – no additional painting necessary

• Reduced scrap rate (e.g. no sink marks occurred through bushes)

D:/Präsentationen/DOW Chemical/LFI production.wmv

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LFI In-Mould Painting

Production steps In Mould Paint

LFI

Primer

• Spraying Barrier Coat India

Material supplied by DOW Chemical

Thickness Barrier Coat 1mm

• Final step applying LFI onto Barrier coat

Material supplied by Dow Chemical (bez.

Thickness LFI 4mm

3 rd. Step

1st. Step

2.nd Step

• Applying In mould painting

Colour Supplied by Sonneborn & Rick UK based Company

Thickness Barrier Coat 0.2mm

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Application:

• Mobile Home

• PUR LFI with thermoformed Skin

Innovation:

• LFI processing technology RIM STAR and LFI mixing head

• Manufacturing of huge exterior body panel (2420 x 1600 x 20)

Benefit:

• “High surface quality” by using Thermoformed Skin

• One step process – no additional painting necessary

• Reduced scrap rate (e.g. no sink marks occurred through inserts)

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Polystyrene 2-D LFI-Part 3-D Design

Wood-Polystyrene-

Steel sandwich

LFI/GF10 -

ABS/PMMA

Part thickness

35 mm 20 mm

Weight per m²

5 kg 4,5 kg

Heat transfer

1,08 K 1,1 K

K-Value Lambda

0,042 0,031

Density g/cm³

0,3-0,35 0,3-0,4

Längenänderung-Koeff. %

0,025 0,030


Properties of LFI exterior Panel

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Engine Encapsulation Jehil Urethane Korea

Glass Content: 30%

Density: 0,6 g/cm³

Wall thickness: 2,5 - 8,0 mm

Heat resistant up to 150° C

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Hat rack Audi A3

Honeycomp spacer

LFI layer 2

LFI layer 1

decor

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Application Examples LFI Honeycomb Technology

Interior – Luggage Compartment: LFI Honeycomb Technology

D:/Präsentationen/Conferences/PU China 2011/Fibre Composite/LFI Shuttle_Rohschnitt_04_12_07.wmv

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glass roving's are cutted in the cutting unit

glass air rips the glass fibers open and accelerates them in the chute

glass stream fly's into the PU-Spray cone, is coated and strikes on the tool

Reaction Technologies – Fiber spray

D:/Fibre Spray System/spray_5.avi

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Spray Head FCS Process

State of the art fiber wetting

Chopper at Robot

no chopper at mixing head

easy access to part

Fiber quantity adjustable

Mixing head

Glass filaments are thoroughly wetted wit PU

No black/white flat spots

Reaction mixture ca be sprayed upwards

No glass filaments input from the side

Outstanding wetting performance for all fillers

Up to 4 components possible

Fiber supply

No fiber fly

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Storage system for glass fiber roving

High volume production solution

Piston Metering

For filled material

Material cost

reduction due to use of

cheap fillers

Control Panel

PUC O8 System

Easy control of all

relevant process

parameters

Mixing head cleaner

Fast / easy cleaning

Cutting Unit mounted

at the robot

Robot

Easy distribution of

material

D:/Präsentationen/Fibre Spray System/4-component Fibre Composite Spraying.wmv

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2.

• enable producers to

manufacture glass or natural

fibers reinforced PU composites

• light weight constructed parts

by utilizing honeycomb paper as

a sandwich structure

• Surface technologies

In mould painting

Foil, Barrier coating, textile,

Gel coat


FCS Fibre Composite Spraying – Main Advantages

2.

Flexible

Part properties

3.

System-

partnership

1.

Economical production of

Small batches

3.

• KM as system supplier

Metering Unit /Robot

Tools by ACS

Parts evaluation by

Automotive testing

department

1.

• Single tool half necessary

• Cost effective tool material

(resin or aluminum tools possible)

• No mould carrier required

• fast tool change

FCS

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Exterior cladding parts

D:/Präsentationen/Fibre Spray System/2010_FCS_4-component.wmv

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Fiber reinforcement partial

D:/Präsentationen/Fibre Spray System/Baypreg.wmv

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RTM Technology

Resin Transfer Molding

Principle

Resin and hardener are metered separately and mixed in a

high pressure process just before the mix is injected into the

closed mold

Technology

The resins used in RTM are two-component fast-curing low

emission systems.

Cycle times are fast and handling is simplified. Both sides of

the part have good surface quality. Typically applications for

RTM are parts with high fiber concentrations and class-A

surfaces. Repeatable part dimensions is key feature of the

process.

Customer benefit

Ideal for production of large volumes of high-strength parts

with good quality surface - Material proportions and part

design can be adjusted to meet specifications


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2.

• Self cleaning mixing head

• consistent chemical

temperature inside the

metering unit up to

120°C/250°F

Unbeatable combination of properties Basic process advantages

2.

consitent Process

High Repeatability

3.

High

Productivity

1.

Excellent Part

Properties

3.

• Relatively short cycle

times compared to low

pressure process

• IMP capable

• High degree of

automation possible

1.

• Distinguished mechanical

properties - bidirectional

• High surface quality

• Paintable on both sides of

the part

RTM


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Target light weight design

Structural body parts

Roof

Underbody structure

Bumper

Side Frame

Source:Alcan


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Application:

• Side Plate

• Epoxy with carbon fiber mat

Innovation:

• Visible carbon fiber matrix

• Mixing head with internal release agent system

• Pressure controlled inject - no fiber disorientation

Value:

• Very high mechanical impact strength

• Low weight

• Production system, many possibilities - development of faster systems

Application

Automotive - Exterior

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Application:

• Roof module


Innovation:

• Visible carbon fiber matrix

• Mixing head with internal mold release agent system

• Pressure controlled infusion - no fiber disorientation

Benefit:


• Low weight


Application

Automotive - Exterior

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Applications

Automotive

Application:

• Cross – Beam / BMW


Innovation:

• Piston dosing unit for RTM

• Mixing head MK 6/10-ULKP2KVV

• Injection into closed mold

Value:


• Low weight


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Application references

Transportation - Exterior

Application:

• Side Panel

• Epoxy with carbon fiber mat / rigid foam core

Innovation:

• Further weight reduction due to light weight foam core

• Mixing head with internal release agent system

• Injection into closed mold

Value:


• Low weight


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RTM Technology

weight reduction potential

source: www.audi.de

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Target light weight design

Structural body parts – future car design

Bildquelle Internet

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Thank you for listening

KraussMaffei Technologies GmbH

Manuel Weindl

Area Sales Manager

Product manager Composite

Krauss-Maffei-Strasse 2

80997 Munich

Germany

Phone +49 (0)89 8899-3177

[email protected]

www.kraussmaffei.com

Your point of contact for systems and solutions Latin-American

Documents

Source: Sabic KraussMaffei Fiber Composites Technologies