LFTs | composites “The European car industry currently leads in LFT
PP consumption, with VW, PSA and Renault the leading European adopters of the technology. Ford is the leader among the North American car makers,” says Nash. “While Europe is the largest regional market today, in the future China is likely to become an important marketplace for LFTs. Companies such as VW have already introduced LFT components in their locally- manufactured models.” Examples of VW’s use of LFTs include the under body shielding manufactured by Polytec Group for the A5/ PQ35 platform (the base for a number of Volkswagen Group models including the Golf, Audi A3, Seat Leon and Skoda Octavia) using its LFT-D processing equip- ment. Polytec also produces the front end structure for the Skoda Fabia using the same technology. It is understood to have capacity to make up to 2.4 million LFT-D parts a year. Meanwhile, BMW uses a Nepol LFT-G PP supplied by
Borealis for the instrument panel carrier used on the current 7 Series car. The LFT-G PP containing 20% glass fibre is used in place of the PPE/PS blend containing 10% glass fibre on the preceding model. Confidence in the outlook for the LFT’s market is also
displayed by Eric Martin, business development manager at Belgium-based 3B Fibreglass, who last year told Compounding World he expects to see annual growth rates of above 10% for LFT products over the next two years. He says that automotive industry applications account for up to 85% of the LFT market today, most of which is PP-based products.
Automotive innovation One of the most innovative automotive LFT-G PP applications in production today is the instrument panel carrier for the latest version of Ford’s Escape and Kuga SUV models. The part, which is produced in a Stamax 20% glass reinforced LFT PP grade from Sabic Innova- tive Plastics by Tier One component maker Faurecia, is further lightened using the Mucell microcellular mould- ing process developed by Trexel in the US. The novel combination of LFT and foam moulding
secured the Grand Award in last year’s SPE Automotive Innovation Awards competition for Faurecia. Compared to a solid part, the microcellular foam moulded carrier weighs around half a kilo less, and it is moulded on a 15% shorter cycle time with 45% less clamp tonnage. This combination of benefits is estimated to translate to a saving of around $3 per vehicle for Ford on top of associated fuel savings. Trexel says the LFT carrier is
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currently the largest automotive component to be moulded using the MuCell process. It is also the first Ford instrument panel carrier to be produced using the Trexel system, although the car maker uses the technology in a number of engine cover and HVAC parts. US-headquartered RTP Company also confirms
expected double digit growth rates for the LFTs market and particularly strong demand from the car industry in Europe. This encouraged the company to switch its LFT compound production in Europe in 2010 from Beaune in France to its new facility at Ladenburg in Germany, where it was able to up LFT capacity. “We are seeing very nice growth [in LFTs] and what
we have seen in recent years is why we invested in Europe,” says Eric Lee, RTP’s business manager for structural products. As part of a programme designed to bring its presence in the LFT market in
Europe in line with its stronger North American position, Lee says the
company has introduced new LFT PP grades that specifically address European automotive industry durability and emission requirements. VLF PP Black is available in 40% and
50% long glass fibre reinforced PP variants. Intended for interior cabin applications, it meets the emission requirements of the VDA 277 VOC automotive standard. VLF PP+UV Black is a 30% long glass fibre reinforced PP
for outdoor automotive applications that displays a negligible colour shift. Billed as an alternative to traditional structural compounds used for automotive trim elements, mirror housings, and luggage
racking, it is said to provide a Delta E value shift of
Left: Hella selected a 50% glass rein- forced low emission grade of Celstran LFT PP from Ticona for this accelerator pedal
January 2012 | COMPOUNDING WORLD 53
Above: RTP’s
LFT compounds on this
Leatherman pocket knife handle
demonstrate the versatility of the materi- als for even small parts
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