COMPOSITES | LFTs


Above: The sunroof frame in the Kia Sorrento is produced using a flat glass reinforced LFT from GS Caltex


component meets Volkswagen’s demanding static and dynamic loading requirements as well as complying with its limits on emissions, fogging, and odour. According to Borealis, the GB416LF grade was specifically formulated for use in tailgate carriers and visible structural parts. The 40% glass fibre- reinforced low emission material provides a flexural modulus of 8,500 MPa, notched Charpy impact strength of 28 kJ/m2


, HDT of 160°C, MFR of 2 g/ min (230°C/2.16kg), and density of 1.24 g/cm3


Right: This hybrid truck toolbox is produced for Chinese truck maker Dong- feng using an LFT hybrid moulding process, reducing


weight by 30% compared to steel


said to offer very good surface aesthet- ics and can be coloured, eliminating the need for additional surface finishing steps such as painting in many cases. Another novel applica-


tion of LFT technology for production of large parts can seen in a sunroof frame developed for Hyundai Group by Inalfa Roof Systems Korea together with LFT producer GS Caltex Corporation. Fitted to the 2022 model year Kia Sorento and a number of other Hyundai Group models, the part won first place in the Body Exterior category of the 2022 North American SPE Automotive Awards competition. The PA6-based LFT used for the part combines two novel technologies. Firstly, it uses a flat profile glass reinforcement, which is claimed to provide improved dimensional stability and 10-times lower warpage than a conventional round fibre. Second- ly, it uses GS Caltex’s twist pultrusion LFT produc- tion technology, which is claimed to allow fibre lengths greater than the actual cut pellet length to be achieved. The developers say that conversion of the part from metal resulted in a 51% weight saving and


36 COMPOUNDING WORLD | March 2023 . It is


reduced the total part count from 33 to four. Warpage of the 40% flat glass reinforced part was similar to a PA6-based LFT with 20% carbon fibre reinforcement but cost was 24% lower. Last year, SABIC announced that Chinese truck manufacturer Dongfeng is using its Stamax LFT-PP material to produce chassis-mounted toolboxes in a hybrid moulding process, reducing part weight by 30% compared to a steel alternative with no loss of stiffness. The hybrid production process combines placement of pre-formed unidirectionally rein- forced PP composite tapes, in this case produced by Chinese company Qiyi Tech, into the mould then overmoulding with the Stamax LFT. The inserts add stiffness and strength to critical areas of the part, enabling the use of thinner-wall sections in less stressed areas to further reduce weight. Compared to steel, the conventional material for truck toolbox applications, SABIC’s plastic compos- ite hybrid solution expands design options, enables the consolidation of parts, and avoids secondary operations that can add costs and prevent high-volume production. The plastic composite solution reduces the


weight of the toolbox by approximately 30 percent (from 6 to 4 kg) without sacrificing the stiffness, toughness, or strength required for this utility application. “By combining two different


materials, our solution im- proves both performance and processability,” according to Abdullah Al-Otaibi, General Manager ETP and Market Solutions at SABIC. “Now


that this composite technology is validated and in mass production


with Dongfeng, we see many other automotive applications that could benefit.” Examples include tailgates, front-end modules and battery housings.


CLICK ON THE LINKS FOR MORE INFORMATION: � www.celanese.com � www.teknorapex.com � www.lehvoss.de � https://akro-plastic.com/ � https://feddem.com/ � IPS https://pelletizing.de/en/ � www.avient.com � www.polyplastics.com � www.borealisgroup.com � www.gscaltex.com � www.sabic.com


www.compoundingworld.com


IMAGE: KIA MOTORS


IMAGE: SABIC


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