LFTs | composites The Spriform process involves thermoforming the pre-
heated continuous fibre reinforced sheet material, which contains up to 50% glass, in the injection mould before selectively over-moulding and encapsulating the formed sheet with direct compounded LFT PA. The LFT-D PA compound is produced on an injection moulding com- pounding (IMC) machine manufactured by KraussMaffei. Spriform project partners believe the technique,
which combines the strength of a glass mat thermoplas- tic with the function integration of an injection moulding, is capable of producing parts that exhibit high levels of strength and energy absorption at lighter weight than metal equivalents and at lower cost than metal-hybrids. Audi estimates a weight saving of up to 20% could be achieved for a Spriform bumper beam compared to current aluminium designs.
bars are said to be cost competitive with steel and faster to manufac- ture than thermoset composite alternatives. PlastiComp says it is keen to work
with existing rebar suppliers or users to establish whether thermoplastic could find a place in the construction sector. Meanwhile, Mexican construction firm Meccano de
Mexico is already using LFTs to produce the forms used in casting of concrete foundations. Injection moulded in an LNP Verton from Sabic Innovative Plastics, the LFT forms measure up to 1,000mm by 600mm and are said to be lighter, quicker to assemble and more durable than steel.
Developing a hybrid future So where may LFT processing technology go next? The improvements in rigidity and durability over short fibre reinforced polymers have already seen LFTs provide an alternative to hybrid metal/polymer structures for moulded parts such as automotive front ends. The next step may be to use LFTs as part of all polymer-based hybrid composite structures, as studied in the recently completed Spriform project. Funded by Germany’s BMBF (the Federal Ministry for
Education and Research), the three year project involved the development of a processing method that combined thermoforming of continuous fibre reinforced thermo- plastic composite sheets with injection moulding of long fibre thermoplastics. Partners included car maker Audi, composite sheet maker Bond-Laminates, the German Institute for Composite Materials (IVW), forming specialist Jacob Plastics, polymer producer Lanxess and machinery maker KraussMaffei.
www.compoundingworld.com January 2012 | CoMPouNDING WoRLD 59
Click on the links for more information: ❙
www.strategyr.com ❙
www.amiplastics.com ❙
www.ticona.com ❙
www.sabic-ip.com ❙
www.jnc-corp.co.jp
❙
www.dieffenbacher.de ❙
www.kraussmaffei.com ❙
www.polytec-group.com ❙
www.borealisgroup.com ❙
www.3b-fibreglass.com ❙
www.trexel.com ❙
www.rtpcompany.com ❙
www.polyone.com ❙
www.basf.com ❙
www.plasticomp.com ❙
www.lanxess.com
Below:
Moulded in BASF’s
Ultramid
Structure PA LFT, these
connectors are used in garden tools by
Freund-Victoria
Left: BASF says its Smart car concept project showed that Ultramid Structure LFT-G PA could slash 30% of the weight of an alloy wheel
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