TECHNOLOGY | LFTs
Right: Detail from a Ford Focus door carrier panel showing how ribbing in LFT-PP is over-moulded onto a
continuous fibre reinforced PP sheet
Kingfa is a major producer of LFTs, but the company is not putting all of its eggs in one basket. Its subsidiary Guangzhou Kingfa Carbon Fiber Materials Development Co worked closely with Brose to develop a KingPly continuous fibre reinforced sheet material for mass production of the lightweight door module carrier. Replacing a conventional 30% glass reinforced LFT-PP compo- nent, the new design realised a 35% weight saving compared with no compromise in performance. According to Cao, this translates to a saving of more than 1kg per car. The new carrier combines the Kingpla sheet with
an LFT. It is a one step process that combines forming of the thermoplastics composite sheet with injection moulding of the overmoulded rib structure in the same tool.
Development cycles One of the most visually striking of new applica- tions in LFTs — and a rare example of a non-PP development is an electric-bike with injection moulded composite frame and wheels. Monaco- based Stajvelo selected Solvay’s long-fibre Xencor polyarylamide (PARA) compound based on its ability to meet stringent structural, mechanical, and aesthetic requirements. Solvay says the Xencor PARA LFT significantly
Below: PolyOne solved an EMI issue for an EV connector by offering a PA-based LFT containing long nickel-coated carbon fibre
extends the performance of its Ixef PARA compounds. The company’s Global LFT Manager Eric Martin said at K2019 the new material was evidence of the considerable progress it has made in integrating the LFT technology it acquired through the purchase of EPIC Polymers back in 2015 with its pre-existing high performance polymers (a Ryton grade is in development). The frame and wheels of the Stajvelo e-bike together weigh just 9kg. Martin said that the Xencor Para LFT material retains the very high
quality surface finish that characterises the company’s standard IXEF polyarylamide — the cycle parts only required degreasing before paint application. A further example of novel LFT application comes
from PolyOne, with its Surround EMI/RFI Shielding Formulation (a PA66-based compound containing long nickel-coated carbon fibre). It was approached by a global automotive Tier One that was develop- ing the high voltage electrical distribution system for a European OEM’s electric vehicle platform and was running into problems with electromagnetic interference (EMI). Engineers pinpointed EMI leakage at the connection point between the high voltage inverter and traction motor. The existing material used for these connectors was a non-conductive plastic compound, which allowed for snap-in component assembly and was lightweight but gave no EMI protection. The PA66-based Surround shielding compound met the EMI shielding requirements and easily dropped into the existing design with no extra assembly and without adding weight.
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.owenscorning.com �
www.songwon.com �
www.sp-protec.com �
www.sinoalloy.com �
www.dieffenbacher.com �
www.arburg.com �
www.roechling.com �
www.kingfa.com.cn �
www.solvay.com �
www.polyone.com
34 COMPOUNDING WORLD | March 2020
www.compoundingworld.com
IMAGE: POLYONE/GETTY IMAGES
IMAGE: KINGFA
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