Metalerstatning med PP, PA6 og PA66 armeret med lange fibre v. Johnny Bjarnholt-Olsen, Biesterfeld Nordic

Technical Center, Applied Development Team Working with

Syddansk Universitet, Odense March 9th

Plastic Raw Material Day

www.kopla.com

Long Fiber Material DevelopmentJohnny Bjarnholt-Olsen

1

www.biesterfeld-plastic.se

www.themegallery.com

� Why LFRT (Long Fiber Reinforced Thermoplastic)?� Why LFRT (Long Fiber Reinforced Thermoplastic)?

Market Trends:• Metal Replacement• Light Weight

Automotive:• Lower Emissions• Higher Mileage• More Safety (e.g. shorter breaking distance)

Industrial & Consumer:• Furniture (Chairs)• Gardening (Industrial)• Ski/Snowboard Bindings• Windmills (Accessories, Cabinets)• Windows• Etc.

2


� LFT (Long Fiber Reinforced Thermoplastic)� LFT (Long Fiber Reinforced Thermoplastic)

KOPLA long fiber reinforced thermoplastics (LFRT or LFT)

It comes from pultrusion process as below picture and it has much better mechanical properties and toughness than short fiber reinforced material. Pellet length is usually 9mm to 12mm and roving fiber (non-broken fiber, usually 20%-60%) is impregnated in melted polymer.

3


� LFT (Long Fiber Reinforced Thermoplastic)� LFT (Long Fiber Reinforced Thermoplastic)

■ LFT Feature

: Stiffness & Toughness

� High stiffness / high temperature

� Toughness & impact strength

� Low Temperature

� High creep resistance vs. std. GF

� Excellent dimensional stability & low warpage

� Outstanding fatigue performance

� Good surface appearance

� High productivity & cost competitiveness

4


� LFT Sub-Replacement Development� LFT Sub-Replacement Development

Advantages PP LFR vs. PA LFR:• Lower price• Lower Density• Conditioning not required

5

www.themegallery.comLONG-GLASS FIBER

KOPLA® LFT KPL1020~1050 (PP LGF 20~60)

KOPLA ® LFT KNL1030~1060 (PA6 LGF 30~60)

KOPLA ® LFT KDL1030~1060 (PA66 LGF 30~60)

KOPLA ® LFT KXL10#0~1060 (X resin LGF #~60)

LONG-CARBON FIBER

KOPLA® LFT KNLC1030~1050 (PA6 LCF 20~50)

KOPLA® LFT KDLC1030~1050 (PA66 LCF 20~50)

KOPLA® LFT KXLC1030~1050 (X resin LCF 20~50)

KOPLA® LFT Product RangeOur LFT product consists of Polypropylene, Polyamide-6, Polyamide-66 and tailor-made polymer grades reinforced with 20 to 60% long-glass fiber and also long-carbon fiber

LONG-GLASS FIBER

6


� Long Fiber Development� Long Fiber Development

Runner & Sprue Designfor Less Fiber Breakage

Runner & Sprue Designfor Less Fiber Breakage

7



Low Compression Screwfor less fiber breakage

Nozzle Size Optimizationfor less fiber breakge

8



Stiffness & Strength Variationthrough Gate Position

Estimate Fiber Breakage Level

9



Enhance weld line strength

Weld Line Location by CAE

Weld line

Hole

Flow Direction

10


�GM M2XX Passenger Airbag Housing�GM M2XX Passenger Airbag Housing

• Application : Passenger Airbag Housing

• Material Change : From PA6+GF40% � PP + Long Glass Fiber 30%

• Weight Reduction : 14% Reduced

[PA6 � 710g, PP � 610g]

PA6+GF40% PP+LGF30%

11


�Structural Analysis Support�Structural Analysis Support 12


�Injection Molding Analysis Support�Injection Molding Analysis Support

Valve open time : 2.0sec, Reference

2cavity

Detail View

Flow Animation

13


�Material Data�Material Data

Test Item Method UnitCurrent Material New Material

PA6-GF40(Impact modified)

PP-LGF30(Impact modified)

Specific Gravity ASTM D792 - 1.41 1.11

Tensile Strength ASTM D638 MPa 180 115

Flexural Strength ASTM D790 MPa 250 120

Flexural Modulus ASTM D790 MPa 8500 5000

Izod Impact (23℃) ASTM D256 J/m 280 310

Izod Impact (-30℃) ASTM D256 J/m 170 350

H.D.T (1.82MPa) ASTM D648 ℃ 205 159

14


�Safety Belt Spool�Safety Belt Spool

• Application : Safety Belt Spool

• Material Change : From ALDC � PA66 + Long Glass Fiber 55~60%

• Weight Reduction : 27% Reduced(93g � 68g)

• Production Cost Reduction

ALDC PA66+LGF55~60

15


� CAE Support� CAE Support 16



Test Item Method Unit PA66-LGF60

Specific Gravity ASTM D792 - 1.65

Tensile Strength ASTM D638 MPa 310

Flexural Strength ASTM D790 MPa 400

Flexural Modulus ASTM D790 MPa 18000

Izod Impact (23℃) ASTM D256 J/m 480

H.D.T (1.82MPa) ASTM D648 ℃ 260

17


�Panorama Sunroof Frame�Panorama Sunroof Frame

• Application : Panorama Sunroof Frame

• Material Change : From ALDC � PA6 + Long Carbon Fiber 20%

• Weight Reduction : 65.9% Reduced(13.8kg � 4.7kg)

• Production Cost Reduction

PA6+LCF20

18


� CAE Support� CAE Support

Hot runner valve type system apply

Flow animation

19



Test Item Method UnitPA6-LCF20

(Impact modified)

Specific Gravity ASTM D792 - 1.19

Tensile Strength ASTM D638 MPa 264

Flexural Strength ASTM D790 MPa 273

Flexural Modulus ASTM D790 MPa 9910

Izod Impact (23℃) ASTM D256 J/m 130

Izod Impact (-30℃) ASTM D256 J/m 115

H.D.T (1.82MPa) ASTM D648 ℃ 220

20


�Engine Cover (Porous Material ->LGF+GB)�Engine Cover (Porous Material ->LGF+GB)

• Application : Engine Cover

• Material Change : From PP-(GF+MF)40% � PP-Long Glass Fiber 20%+Glass Bubble 10%

• Weight Reduction : 15~20% Reduced

PP-(GF+MF)40 PP-LGF20+GB10

21


■ Manufacturing method

-. PP-LGF40 + PP-GB20 (50% + 50% Blending) -> PP-(LGF20 +GB10)

PP-LGF40

GB

PP-GB20

�Engine Cover (Porous Material ->LGF+GB)�Engine Cover (Porous Material ->LGF+GB) 22


■ Cross-section of porous material

�Engine Cover (Porous Material ->LGF+GB)�Engine Cover (Porous Material ->LGF+GB)

※ Key technology

Minimized method to microdispersity and crush rate of porous fillers

LGF

GB

23


� CAE Support� CAE Support

Compare gate type

Modal Analysis

Harmonic Analysis

24



Test Item Method UnitCurrent Material New Material

PP-GF25+MF15 PP-LGF20+GB10

Specific Gravity ASTM D792 - 1.21 0.97

Tensile Strength ASTM D638 MPa 75 85

Flexural Strength ASTM D790 MPa 105 100

Flexural Modulus ASTM D790 MPa 5400 4500

Izod Impact(23℃)

ASTM D256 J/m 110 130

Izod Impact (-30℃) ASTM D256 J/m 70 120

H.D.T (1.82MPa) ASTM D648 ℃ 153 156

25

Technical Center, Applied Development Team Working with

Questions?

Please visit our websiteswww.kopla.comwww.biesterfeld-plastic.se

Biesterfeld Nordic DKJohnny Bjarnholt-Olsen

E-mail: [email protected].: +45 26226381

26

Engineering

Metalerstatning med PP, PA6 og PA66 armeret med lange fibre v. Johnny Bjarnholt-Olsen, Biesterfeld Nordic