This page contains a Flash digital edition of a book.
show preview | Composites

medium-sized processor could use this technology,” he said.

BASF’s Ultracom laminates are based on woven

Above: Arburg will use its D-LFT technol- ogy to over- mould a continuous thermoplastic sheet on its stand at the show

production system in its technical center for thermo- plastics processing at Ludwigshafen in Germany. Since March of this year, this equipment – based around a 300 tonne KraussMaffei moulding machine and a Georg Kaufmann test mould – has been used to produce multifunctional composite test specimens by in-mould forming and overmoulding. Visitors to the BASF stand at K will be able to see the complex part. According to Dr Reinhard Jakobi, head of processing

technology, this process represents the most promising approach for production of structural components, allowing ribs, bosses and other reinforcing structures to be placed on the component in the same mould that is used for forming the laminate. The system in the BASF technical centre is designed

to allow the company’s engineering team to explore every aspect of part design. The 40cm by 40cm by 4.5cm test component has been developed for use with 1.5mm thick laminates and up to 3mm thick moulded-on functional elements. It can model overmoulded edges and can be used to assess the impact of long flow paths, formed mounting holes, stitch elements (where the overmoulded material is injected through the element), and rib structures on mechanical and crash perfor- mance.

A multi-axis robot is used to manipulate three

Right: this 500mm long structural part will be

produced on a

40s cycle on the Arburg stand


laminate clamping frames through the various steps of the production process. By making it possible to heat a part, mould a part and remove a part from the frame simultaneously, Jakobi says cycle times of one minute can be achieved on its test part. “But this is not optimized, we think we could go down to 50s,” he says. “When you use three frames simultaneously you are much more productive but you need a robot. Our automation partner is FPT but this is not a major change from a regular injection machine – I think any

INJECTION WORLD | October 2013

fabrics and unidirectional (UD) tapes that are fully impregnated with Ultramid PA or Ultradur PBT resins. The thermoplastic composite laminates have been developed together with composites manufacturer TenCate and glass fibre producer Owens Corning. At the K show, the company will introduce two packages. For high stiffness applications it has developed an Ultralaminate based on polyamide 6 (or an Ultratape if highly directed reinforcements are needed) for use in combination with a 60% glass fibre reinforced Ultramid G12 COM overmoulding resin. For crash-loaded applications requiring high impact strength, it offers a PA6-based Ultralaminate or Ultratape in combination with an Ultramid ZG7 COM overmoulding resin. While the Ultracom material packages are new, the

process technology has been under development for some time and is already used to produce the seat pan for the Opel Astra OPC car, which was introduced last year. This component was developed using an extension of BASF’s Ultrasim analysis tool, which is able to simulate the anisotropic long fibre distribution in the part. Jacobi says the company is currently working on another active project.

With its acquisition in 2012 of Germany’s Bond

Laminates, Lanxess has positioned itself for an expected rush of activity in the thermoplastics compos- ites sector. “We are now one of the few thermoplastics manufacturers in the world that can supply performance composites and compounds proven in large-scale production, complete with the associated applications know-how for the volume production of lightweight components,” says Dr Michael Zobel, head of the company’s High Performance Materials business unit. Bond Laminates manufactures a range of continu-

ous fibre reinforced thermoplastic sheet materials under the Tepex name. The primary matrix for the materials is polyamide, although alternative polymers such as PP, TPU and PPS could also be used. Rein- forcement options include glass, carbon or aramid fibres. Tepex materials are characterised by low weight and

high strength. Lanxess says Tepex has a density of between

Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82