LFTs | TECHNOLOGY
Figure 1: The global market for LFT PP
Source: AMI Consulting 2021
vehicle producers as a new way of saving weight. The shift towards electric and hybrid vehicles,
while threatening some existing polymer applica- tions, is creating new opportunities for LFT PP as designers rethink concepts and adopt new approaches. The report cites the example of the Tesla ‘frunk’ — the trunk, or storage compartment, at the front. This makes use of the space at the front of the vehicle for storage but needs to be designed with the conventional automotive front-end ability to absorb impact in a collision. The strong interest in LFT materials is confirmed by US-based RTP Company, which offers an extensive range of LFT materials. “Replacing metal parts or over-engineered short glass fibre com- pounds remain the primary growth opportunities,” says Zach Halverson, Structural Products Business Manager at the company. “For example, short glass fibre polyamide compounds can often be success- fully replaced with long fibre polypropylene compounds, offering a lower cost and lower density solution.” RTP also offers long fibre technology in engi- neering and high-performance base polymers such as PEEK, PPA, PEI and PPS. These combine the desirable mechanical and thermal attributes of the polymers with the additional benefits of long fibre reinforcement. They are said to be good options for metal replacement in especially demanding environments, such as in the oil and gas industry, where other materials fall short (Figure 2). Halverson says the automotive industry contin- ues to be the largest consumer of long fibre thermoplastics and that any disruptions in that sector inevitably influence usage. 2021 was a particularly volatile year for the car industry, especially with supply chain issues, but he expects RTP to see strong demand through 2022 as the automotive industry works through its build backlog. He also expects to benefit from further organic growth and additional parts being con- verted to LFTs to meet weight reduction and fuel efficiency goals.
As the major end-user of LFTs, the performance 28 COMPOUNDING WORLD | March 2022
needs of the automotive industry are a key driver in LFT development. Current challenges include increasingly stringent VOC limits, the ability to withstand long-term heat ageing for more than 1,000 hours at 150°C (Figure 3), more robust UV resistance, and the ability to achieve highly aesthetic Class A surface finishes directly out of the mould. Often several of these requirements are demanded in one application. To address these automotive challenges, RTP
says its Product Development Team works in close collaboration with leading additive technology suppliers, performing extensive experimental compounding of new formulations. The company says it is also highly invested in the best com- pounding processes, while regional availability enables it to offer the same product consistently in any region of the world. “One of the latest products developed by RTP
Company is a 40% long fibre polypropylene compound for automotive liftgates,” says Halver- son. “Automotive liftgates require good UV resistance and mechanical properties, Class A surface finish with no visible fibres, long flow paths, low VOCs, and be colourable to tight colour targets. This material flows very well to fill large parts with long flow paths while achieving excellent aesthetics and good mechanical performance.” Alongside performance, sustainability is now
very often a mandated requirement, according to Halverson. “RTP Company has been working on a line of sustainable long fibre polypropylene products to support these initiatives. Our Product
Figure 2: Tensile strength values for a range of VLF 40% long glass fibre reinforced performance polymer compounds from RTP Source: RTP Company
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