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TECHNOLOGY | REINFORCEMENTS


Right: The Rome Black Label snow- board com- bines PolyOne continuous fibre reinforced thermoplastic composite and short glass


compound in its overmoulded construction


testing systems for material analysis. “Hybrid overmoulding with thermoplastic composites is an emerging technology, expanding into industries from automotive to consumer electronics and sporting goods,” says Mike Mosley, General Manager Advanced Composites at PolyOne. “Our new lab will enable collaboration with product designers and engineers looking to improve performance, reduce weight, or consolidate parts with continuous fibre reinforced thermoplastic tapes and laminates. We can use injection and compression overmoulding to help them meet their most challenging performance requirements and bring innovative products to market.”


Johns Manville has been sampling a new line


Below: Frame and wheels of Stajvelo’s new electric cycle are injection moulded in a polyacrylamide based perfor- mance LFT from Solvay


of continuous fibre reinforced thermoplastic sheets during this year, following their launch at last year’s Fakuma trade fair in Germany. “The OS-6 series of nylon 6 based organosheets are an ideal structural reinforcement solution for lightweight parts. They are suitable for high throughput manufacturing processes, such as injection overmoulding and compression moulding,” says Matthew Walp, New Business Innovation Leader in JM’s Corporate R&D. The sheets are produced using a proprietary technology that is said to provide greater control of fibre content. The company claims that crimped and non-crimped fabrics as heavy as 2,500 g/m2 can be fully impregnated in one step, eliminating the need for lamination/consolidation steps to build up thickness.


Lifting limits in LFTs Interest is also growing in long-fibre reinforced (LFT) compounds, with the key drivers being weight saving and part integration. While most of the volume in the LFT market is in PP compounds,


some are exploring more exotic matrix materials. Solvay is an example, and is supplying an LFT based on its Ixef PARA polyacrylamide engineering resin to French company Stajvelo for production of an injection moulded electric bicycle. The Xencor PARA LFT significantly extends the performance capabilities of Solvay’s Ixef PARA compounds, which have successfully replaced metal in medical devices, automotive exteriors, and small appliances where a highly aesthetic surface finish is required. Stajvelo selected Solvay’s Xencor PARA LFT for its ability to meet its stringent structural, mechanical and aesthetic requirements. “Stajvelo’s e-bike design embodies the hard-to-achieve balance between form and function, due in part to Xencor PARA’s unique combination of properties,” says Thierry Manni, Founder and Chief Executive Officer of the cycle maker. “Thanks to Solvay’s polymer expertise and processing technology support, we were able to design a manufacturing process with optimal function integration and time-saving assembly operations. The Xencor PARA LFT compound is used to injection mould the frame and wheels of the cycle. A particular benefit of the Xencor PARA grade is its ability to produce a very smooth as-moulded surface; the parts used on the Stajvelo cycle are painted but the high gloss surface is produced with no surface preparation beyond degreasing. Solvay’s Xencor LFT compounds are available with a wide range of matrix resins, including a pre-commercial PPS version. They


50 COMPOUNDING WORLD | November 2019 www.compoundingworld.com


PHOTO: POLYONE


PHOTO: SOLVAY


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