AUTOMOTIVE | UNDER THE HOOD
Right: Technology demonstrator part developed in the ReLei project
circuiting reactions.” The company adds that
realising cost effective hybrid-lightweight parts and the further integration of functions into plastic parts remains crucial. “When it comes to cost reduction by direct processing, for example with natural or glass fibres for lightweighting or recycling purposes, KraussMaffei has been addressing the direct compounding of parts with single- and twin-screw extruders for several years,” says Würtele. “However, we are working with many industry partners to develop new solutions. As well as FiberForm and their derivatives, there is also the ReLei project and a new combination of reaction processing and injection moulding technology. The Opto-Light 2-K-Composites project will enable photonics within the production cell for high quality manufacturing of functional integrated lightweight plastic parts with different reinforcement combinations.” The FiberForm process works with composite
materials including UD tapes and organosheets. The one-stage process starts with organosheet intake followed by heating. The material is then transferred to an injection mould for forming and the part is then injection moulded and removed. KraussMaffei says that a 49% weight saving can be achieved for a series component compared with steel and it is also cost efficient because of simplified assembly of the parts. In addition FiberForm can be used for plastic and plastic hybrid parts with local reinforcement and be given QR codes for traceability. Under-the-hood applications can include bumper carriers, airbag housings and battery trays. ReLei will also be part of the production process, offering constructive lightweight
Left: A section of a structural automotive demonstrator component of the BMW i3 developed in the Opto- Light project
16 INJECTION WORLD | May 2020
designs that involve recycling from the beginning. These materials have an endless fibre- reinforced top coat with cores of variable
thicknesses to provide stiffness
and strength. The one-shot foam-forming process involves
preheating the thermoplastic sheets and nonwoven cover layers, which are fed into the injection mould. The tool halves are closed and the cover layers preformed. The melt is injected in-between and final shaping of the cover layers is done by melt pressure. The tool halves are opened by a few millimetres and through open compression moulding the melt is foamed using the MuCell process. Opto-Light provides a combination of reaction technology and injection moulding for lightweight material design incorporating photonics. Due to the combination of materials, parts can be designed with high strength and stiffness in combination with a low creep tendency, as well as offering higher design freedom and functionalisation. Currently in production, integration is possible but with long cycle times using continuously reinforced thermosets through resin transfer moulding and wet moulding. Alternatively, with the connection of thermoset laminates and thermoplastic composites in a photonics-enabled process chain based on an injection moulding machine with a turning plate, a high degree of manufacturing integration at low cycle times can be achieved by hybrid moulding through thermoforming and back moulding. Injection moulding machinery manufacturer Sumitomo (SHI) Demag says it is observing a number of trends in the automotive sector for under-the-hood applications. “For exhausted engine vehicles we see a major trend in noise reduction, efficiency, weight reduction, all related to general emission reduction,” says Henrik Langwald, Business Development Director Automotive for Europe. “Additionally, for hybrid vehicles there is a focus on improving and regulating the thermal management of the temperature to ensure the system can adapt to the ambient temperature and maintain comfort for passengers. Trend-wise, the current material mix under-the-hood remains virtually the same. For all-electric vehicles, current trends are focused on improving the protection against the current.
www.injectionworld.com
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