MATERIALS | AUTOMOTIVE
achieved the required stiffness by geometric stiffening, with part elements such as moulded-in ribs. However, the resultant seat base typically had high part thickness, of up to 9 mm, said Lochner. “In the tape sandwich process, we work with very thin single-layer reinforcement materials such as tapes and fabrics with a polypropylene matrix, which are inserted into the injection mould without preheating. The mould cavity is then filled with polypropylene,” said Franz Füreder, Vice President Automotive & Mobility at Engel’s Schwertberg headquarters.
Due to the specific mechanical properties of the sandwich structure, a single-layer reinforcement UD tape was able to meet the stiffness require- ments for the seat base. “This means that the tape sandwich process requires significantly less energy and simpler production cell technology than conventional fibre-reinforced plastic composite methods. At the same time, the production costs drop,” said Füreder.
Below: Engel partnered with KTM Technologies on a thermo- plastic
composite seat base for this KTM motor- cycle
Recyclable The partnership found that the necessary installa- tion space of the seat bottom could be reduced by 66% while the weight could be trimmed by about 26% with use of the UD tape technology. The new sandwich structure, in which the reinforcing fibres are as far away as possible from the neutral fibre, offers maximum stiffness while minimising the number of fibres required, Lochner said. Another advantage of the tape structure is that standard thermoplastics could be used in components exposed to high mechanical stresses, since part performance is driven exclusively by the tape structure. This realisation has cost efficiencies, Engel said.
Engel and KTM Technologies evaluated a variety
of injection moulding grade materials, including bio-based and recycled PP grades in addition to
IMAGE: ENGEL
conventional PP from fossil sources, with the global warming potential (GWP) determined for the various material combinations. Compared to the motorcycle seat base made entirely of virgin PP, the tape sandwich technology reduced the GWP by 27% when also using fossil-based PP. The change in the GWP value was achieved solely by reducing the amount of fossil-based PP. When PP from renewable resources is used, the
GWP value is reduced by 85% compared to the virgin PP seat base. The weight of the seat compo- nent was reduced by 26% in each test case where the UD tape technology was used. “This is possible because even very thin components achieve high stiffness,” said Engel. The consistent use of a single plastic grade with the tape technology also contributes to a reduction of greenhouse gas emissions, Engel said. In combination with tapes from a PP matrix, parts can be created which can be recycled at the end of their service life, said Füreder. In the first use of the UD tape development,
KTM will set up the tape sandwich technology for use with its KTM family of motorcycles. Engel and KTM Technologies plan to evaluate other applica- tions in the mobility industry. They are offering the tape sandwich process jointly. Engel’s organomelt process can form and functionalise thermoplastic sheets and UD tapes in a single integrated process step. Engel developed and produced its IR oven design in-house and this is used to precisely heat the thermoplastic material. An Engel robot transfers the heated sheet into the mould. The IR oven and robot operations are integrated into and displayed on Engel’s CC300 injection moulding machine controller. Reinforcing ribs or assembly elements are overmoulded immediately in the same mould, typically using a thermoplastic from the same matrix material group as the thermoplastic sheet.
Sensor housings “Vehicles are getting smarter and autonomous. There are more complex and various sensor systems for infotainment and safety like a radar system, parking assistance and traffic monitoring,” said Buket Turan, Technical Marketing Manager at Eurotec-EP. “An important parameter is to establish good communications between the vehicle and environment using advanced control systems that can identify and process information coming from sensors. Hence, it is important that sensor housing materials have good mechanical stiffness, creep and fatigue resistance, dimensional stability, and EMI/RF shielding to avoid any safety issues,” Turan said.
34 INJECTION WORLD | January/February 2024
www.injectionworld.com
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