Metalerstatning med PP, PA6 og PA66 armeret med lange fibre v. Johnny Bjarnholt-Olsen, Biesterfeld Nordic

Technical Center, Applied Development Team Working with
Syddansk Universitet, Odense March 9th
Plastic Raw Material Day
www.kopla.com
Long Fiber Material Development
Johnny Bjarnholt-Olsen
1
www.biesterfeld-plastic.se

www.themegallery.com
Why LFRT (Long Fiber Reinforced Thermoplastic)?Why LFRT (Long Fiber Reinforced Thermoplastic)?
Market Trends:
• Metal Replacement
• Light Weight
Automotive:
• Lower Emissions
• Higher Mileage
• More Safety (e.g. shorter breaking distance)
Industrial & Consumer:
• Furniture (Chairs)
• Gardening (Industrial)
• Ski/Snowboard Bindings
• Windmills (Accessories, Cabinets)
• Windows
• Etc.
2

LONG-GLASS FIBER
KOPLA® LFT KPL1020~1050 (PP LGF 20~60)
KOPLA ® LFT KNL1030~1060 (PA6 LGF 30~60)
KOPLA ® LFT KDL1030~1060 (PA66 LGF 30~60)
KOPLA ® LFT KXL10#0~1060 (X resin LGF #~60)
LONG-CARBON FIBER
KOPLA® LFT KNLC1030~1050 (PA6 LCF 20~50)
KOPLA® LFT KDLC1030~1050 (PA66 LCF 20~50)
KOPLA® LFT KXLC1030~1050 (X resin LCF 20~50)
KOPLA® LFT Product Range
Our LFT product consists of Polypropylene, Polyamide-6, Polyamide-66 and tailor-made polymer grades reinforced with 20 to
60% long-glass fiber and also long-carbon fiber
LONG-GLASS FIBER
6

Long Fiber DevelopmentLong Fiber Development
Runner & Sprue Design
for Less Fiber Breakage
Runner & Sprue Design
for Less Fiber Breakage
7

Low Compression Screw
for less fiber breakage
Nozzle Size Optimization
for less fiber breakge
8

Stiffness & Strength Variation
through Gate Position
Estimate Fiber Breakage Level
9

Enhance weld line strength
Weld Line Location by CAE
Weld line
Hole
Flow Direction
10

GM M2XX Passenger Airbag HousingGM M2XX Passenger Airbag Housing
• Application : Passenger Airbag Housing
• Material Change : From PA6+GF40% PP + Long Glass Fiber 30%
• Weight Reduction : 14% Reduced
[PA6 710g, PP 610g]
PA6+GF40% PP+LGF30%
11

Structural Analysis SupportStructural Analysis Support 12

Injection Molding Analysis SupportInjection Molding Analysis Support
Valve open time :
2.0sec, Reference
2cavity
Detail View
Flow Animation
13

Material DataMaterial Data
Test Item Method Unit
Current Material New Material
PA6-GF40
(Impact modified)
PP-LGF30
(Impact modified)
Specific Gravity ASTM D792 - 1.41 1.11
Tensile Strength ASTM D638 MPa 180 115
Flexural Strength ASTM D790 MPa 250 120
Flexural Modulus ASTM D790 MPa 8500 5000
Izod Impact (23℃) ASTM D256 J/m 280 310
Izod Impact (-30℃) ASTM D256 J/m 170 350
H.D.T (1.82MPa) ASTM D648 ℃ 205 159
14

Safety Belt SpoolSafety Belt Spool
• Application : Safety Belt Spool
• Material Change : From ALDC PA66 + Long Glass Fiber 55~60%
• Weight Reduction : 27% Reduced(93g 68g)
• Production Cost Reduction
ALDC PA66+LGF55~60
15

CAE SupportCAE Support 16

Test Item Method Unit PA66-LGF60
Specific Gravity ASTM D792 - 1.65
Tensile Strength ASTM D638 MPa 310
Flexural Strength ASTM D790 MPa 400
Flexural Modulus ASTM D790 MPa 18000
Izod Impact (23℃) ASTM D256 J/m 480
H.D.T (1.82MPa) ASTM D648 ℃ 260
17

Panorama Sunroof FramePanorama Sunroof Frame
• Application : Panorama Sunroof Frame
• Material Change : From ALDC PA6 + Long Carbon Fiber 20%
• Weight Reduction : 65.9% Reduced(13.8kg 4.7kg)
• Production Cost Reduction
PA6+LCF20
18

CAE SupportCAE Support
Hot runner valve type system apply
Flow animation
19

PA6-LCF20
(Impact modified)
Specific Gravity ASTM D792 - 1.19
Tensile Strength ASTM D638 MPa 264
Flexural Strength ASTM D790 MPa 273
Flexural Modulus ASTM D790 MPa 9910
Izod Impact (23℃) ASTM D256 J/m 130
Izod Impact (-30℃) ASTM D256 J/m 115
H.D.T (1.82MPa) ASTM D648 ℃ 220
20

Engine Cover (Porous Material ->LGF+GB)Engine Cover (Porous Material ->LGF+GB)
• Application : Engine Cover
• Material Change : From PP-(GF+MF)40% PP-Long Glass Fiber 20%+Glass Bubble 10%
• Weight Reduction : 15~20% Reduced
PP-(GF+MF)40 PP-LGF20+GB10
21

■ Manufacturing method
-. PP-LGF40 + PP-GB20 (50% + 50% Blending) -> PP-(LGF20 +GB10)
PP-LGF40
GB
PP-GB20
Engine Cover (Porous Material ->LGF+GB)Engine Cover (Porous Material ->LGF+GB) 22

■ Cross-section of porous material
Engine Cover (Porous Material ->LGF+GB)Engine Cover (Porous Material ->LGF+GB)
※ Key technology
Minimized method to microdispersity and crush rate of porous fillers
LGF
GB
23

CAE SupportCAE Support
Compare gate type
Modal Analysis
Harmonic Analysis
24

Current Material New Material
PP-GF25+MF15 PP-LGF20+GB10
Specific Gravity ASTM D792 - 1.21 0.97
Tensile Strength ASTM D638 MPa 75 85
Flexural Strength ASTM D790 MPa 105 100
Flexural Modulus ASTM D790 MPa 5400 4500
Izod Impact
(23℃)
ASTM D256 J/m 110 130
Izod Impact (-30℃) ASTM D256 J/m 70 120
H.D.T (1.82MPa) ASTM D648 ℃ 153 156
25

Technical Center, Applied Development Team Working with
Questions?
Please visit our websites
www.kopla.com
www.biesterfeld-plastic.se
Biesterfeld Nordic DK
Johnny Bjarnholt-Olsen
E-mail: j.olsen@biesterfeld.com
Tel.: +45 26226381
26

Metalerstatning med PP, PA6 og PA66 armeret med lange fibre v. Johnny Bjarnholt-Olsen, Biesterfeld Nordic

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Metalerstatning med PP, PA6 og PA66 armeret med lange fibre v. Johnny Bjarnholt-Olsen, Biesterfeld Nordic