thermoplastic composites | Innovation Right: IKV
developed this Industry 4.0
production cell
to demonstrate on-demand
hybrid TPC pro- duction
able to control the production process, selecting a personalised part from a number of variants, and then have it made. Shot volume, part thickness and the type of fibre reinforcement could all be varied from one shot to the next.
Discontinuous development Not all the activity in high performance thermoplastic composites is in continuous fibre reinforced types. Borealis launched a new Fibremod portfolio of discontinuous carbon fibre reinforced polypropylene injection moulding grades early last year, saying they will help automotive OEMs meet weight reduction, energy and resource efficiency targets as well as improving economics. “Fibremod Carbon is an enabler to improve the
range and costs of electric vehicles (EV),” Borealis claims. “By reducing the total weight of an electric vehicle by 10% the energy consumption from the batteries can be reduced by 5% allowing either significant range extension or downsizing of the battery pack. This is a great benefit for the car manufacturers considering the share of total vehicle weight added by battery packs in long range EVs is approximately 25%. Additionally it helps to reduce costs in this highly competitive environment.”
The new compounds use 0.5-1.0mm long fibres
sourced from long fibre carbon fibre composite production waste. “By enhancing the cost-effective recyclability of cutting-edge materials, Borealis is helping OEMs become more efficient in both economic and environmental terms,” says Nicholas Kolesch, Borealis Head of Marketing Automotive. There are current five Fibremod Carbon grades, with
carbon fibre contents ranging from 6% through to 40%. Target applications for the new materials include automotive timing chain adjusters, pump and headlamp housings, oil pans, seat frames and arm rests, gear shift gates, sunroof frames and tailgate structures. Borealis says the first projects are likely to be commer- cialised during this year.
Fibremod Carbon PP grades are said to boast a lightweighting potential of more than 60% compared to steel. They also outperform short carbon fibre reinforced polyamides
Source: Borealis
Specific material cost increase per kilogram of weight saving of various materials compared with steel
28 INJECTION WORLD | January/February 2017 Source: Borealis
Click on the links for more information: ❙
www.dupont.com ❙
www.lanxess.com ❙
www.bond-laminates.com ❙
www.sabic.com ❙
www.frt.sabic.com (FRT Tapes) ❙
www.plasticomp.com ❙
www.covestro.com ❙
www.victrex.com ❙
www.tencate.com ❙
www.engelglobal.com ❙
www.kurz.de (Leonard Kurz) ❙
www.kraussmaffei.com ❙
www.siebenwurst.de (Christian Siebenwurst) ❙
www.dieffenbacher.de ❙
www.ikv-aachen.de ❙
www.arburg.com ❙
www.gkform.ch (Georg Kaufmann) ❙
www.borealisgroup.com
www.injectionworld.com
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