Source: Sabic KraussMaffei Fiber Composites Technologies
Transcript of 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
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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
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KraussMaffei process technologies for composites
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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KraussMaffei process technologies for composites
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
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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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Application example of LFI:
• Smart
• PU GF15 frame with 2xPMMA and ASA/PC plastic film, 6000 g
Innovation:
• Inetrgration of fixing elements
• Fibre length and volume locally adjusted, no fibre orientation
• Suitable for large body panels
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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.
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Application example of LFI:
• Front Grill
• PU GF25 frame with plastic film,
Innovation:
• Perfect wetting and distribution of the glass fibres
• Fibre length and volume locally adjusted, no fibre orientation
• Suitable for large body panels
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Application example of LFI:
• BMW 6er convertible
• PU GF covered with aliphatic PU system
Innovation:
• Perfect wetting and distribution of the glass fibres
• Fibre length and volume locally adjusted, no fibre orientation
• Exterior body part over molded with aliphatic PU system
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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)
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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
A unbeatable combination of different characteristics
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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KraussMaffei process technologies for composites
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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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
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KraussMaffei process technologies for composites
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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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
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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
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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
A unbeatable combination of different characteristics
FCS Fibre Composite Spraying – Main Advantages
2.
Flexible
Part properties
3.
System-
partnership
1.
Economical production of
Small batches
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• 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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Spray Head FCS Process
Exterior cladding parts
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KraussMaffei process technologies for composites
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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Spray Head FCS Process
Fiber reinforcement partial
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KraussMaffei process technologies for composites
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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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
Benefits – Possibilites – Expectations – Network – Process Equipment
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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
Benefits – Possibilites – Expectations – Network – Process Equipment
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Target light weight design
Structural body parts
Roof
Underbody structure
Bumper
Side Frame
Source:Alcan
Benefits – Possibilites – Expectations – Network – Process Equipment
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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
• Epoxy with carbon fiber mat
Innovation:
• Visible carbon fiber matrix
• Mixing head with internal mold release agent system
• Pressure controlled infusion - no fiber disorientation
Benefit:
• Very high mechanical impact strength
• Low weight
• Production system, many possibilities - development of faster systems
Application
Automotive - Exterior
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Applications
Automotive
Application:
• Cross – Beam / BMW
• Epoxy with carbon fiber mat
Innovation:
• Piston dosing unit for RTM
• Mixing head MK 6/10-ULKP2KVV
• Injection into closed mold
Value:
• Very high mechanical impact strength
• Low weight
• Production system, many possibilities - development of faster systems
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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:
• Very high mechanical impact strength
• Low weight
• Production system, many possibilities - development of faster systems
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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
www.kraussmaffei.com
Your point of contact for systems and solutions Latin-American