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Advancing structural capability of injection molded components with Continuous Fiber Reinforcement
Seat Pan Opel Astra OPC
Calvin Nichols, BASF Corporation
Automotive Solutions Performance Passion Success Continuous Fiber Reinforcement of Injection Molded Parts
UD Tape
Thermo-plastic laminate
Laying of tapes (picture AFPT)
Organosheet (picture IVW)
Reinforced plastic molding
Reinforced plastic molding
Reinforcer Pultruded Tape fully impregnated
Heating One Shot Draping and Overmolding
Types of Semi Finished Products
Automotive Solutions Performance Passion Success
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0
20
40
60
80
100
120
140
0 200 400 600 800 1000 1200 1400 1600 1800
Stiff
ness
[GPa
]
Strength [MPa]
Al
Mg
PA-GF50
PA-GF30 Laminates 0/90 GF
Laminates 0/90 CF
All materials 50 Vol.-% fiber content
Strength [MPa]
Stif
fnes
s [G
Pa]
Source: Fiberforge
Potential of continuous fiber reinforced plastics Carbon vs. glass fibers --- Stiffness vs. Strength
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UD-Tapes CF
UD-Tapes GF
Automotive Solutions Performance Passion Success
Joint development and production of thermoplastic composites: UD-tapes and laminates
BASF: Know-how in research, production and formulation of thermoplastic resins
TenCate Advanced Composites: Expertise in composite manufacturing Advanced tapes and laminates… For structural automotive parts (car body, chassis) Focus on mass production
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BASF and TenCate: Strategic Alliance for Thermoplastic Automotive Composites
Automotive Solutions Performance Passion Success
Measurement Process
Draping / Molding
Material
Part
Integrative Simulation ULTRASIM® for Continous Fiber Reinforced Plastics
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BASF approach: full ULTRASIM® prediction and design level for continuous fiber reinforcement
Automotive Solutions Performance Passion Success
Material Characterization Laminates and Tapes
Tensile Test Orientation
Testing Speed
(Wallthickness)
Humidity
3 Point Bending
Puncture Test
Compression Test
Sheartest
Adhesion of Ribs
Draping
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Drapiereigenschaften IVW, Kaiserslautern
Automotive Solutions Performance Passion Success
Which Type of Semi Finished Material?
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Tapes Parts with areas of highest local anisotropic load distribution
• front seat back rests
Laminates predominantly closed areas, mechanical load rather evenly distributed
seat pans, rear seat backrests, vehicle floors
Automotive Solutions Performance Passion Success
Example: Prototype-Seat Backrest with overmolded Tape Reinforcement
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UD- Fiber reinforcement in high loaded zones Injection molding material in zones of medium load and functional integration
Injection molded PA6
UD-Fiber reinforcement
Overmolded in injection molding
process
Automotive Solutions Performance Passion Success
Automated Tapelaying Available Processes
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Moving Head with laser welding fixation
Moving Table with ultrasonic fixation
Automotive Solutions Performance Passion Success
Consolidation of Tapes Microscopy und Micro-CT
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glass fibers matrix: PA6 Ultramid®
6-layers: 0°/90°/0°/0°/90°/0°
thickness 0,25mm each
60 weight-% glass fibers
before Consolidation after Consolidation
Automotive Solutions Performance Passion Success
Component Test and Validation Dynamic Test, 5.0 m/s Impactor Speed
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After Test
Break between bolts in both CAE and Test
CAE
Automotive Solutions Performance Passion Success
Drop Tower Test Influence of Fiber Length
0
100
200
300
400
500
600
700
0 10 20 30 40 50 60 70Time [ms]
Ene
rgy
[J]
PA6 GF50 23°CPA6 LGF40 23°CPA6 CFRT 23°C
Test Temperature 23°C
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Automotive Solutions Performance Passion Success
Drop Tower Test Influence of Overmolding Material
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PA GF Resin - Standard PA GF Resin “Optimized”
Automotive Solutions Performance Passion Success
Further Potential in Vehicles
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Structures for doors and hatches,
even online paintable
Crash Extensions
Structural Floor
Structural Inserts (A-, B-, C-Pillar, Roof Frame…)
Cross Car Beam
Roof Cross Member
Fire Wall
Frontend Battery Integration
Automotive Solutions Performance Passion Success
Example: Serial Front Seat Pan Opel Astra OPC
Adam Opel AG SeaTcon AG/ SedisTec UG Reinert Kunststofftechnik
Maier Formenbau
Automotive Solutions Performance Passion Success
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Overmolding material Ultramid® PA6 short glass fiber material
Thermoplastic laminate based on Ultramid® PA6 and glass fibers
Serial Front Seat Pan Opel Astra OPC
Automotive Solutions Performance Passion Success
Integration of Relevant Process Steps
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In-Mold Forming Injection Molding Mechanics
Integrative Simulation with ULTRASIM®
Automotive Solutions Performance Passion Success
Optimization of Heating Parameters
Influence parameters: Material properties (absorption,
reflection, thermoconductivity etc.) Type of emitter Emitter control (power profile) Distance, time…
Trials at Krelus Infrared
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Automotive Solutions Performance Passion Success
In-Mold-Forming and Overmolding
mold closing side mold injection side
laminate in open mold
IR heater
19 Cycle time 70 sec
Automotive Solutions Performance Passion Success
Micro CT Testing
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Automotive Solutions Performance Passion Success
Component Testing
m = 25 kg v = 5 - 9 m/s
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Automotive Solutions Performance Passion Success
Seat Testing
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Quelle: SedisTec
Automotive Solutions Performance Passion Success
Wall thickness 1 mm in laminate 45% weight saving Function integration Cost balance
Serial Application in Opel Astra OPC
Automotive Solutions Performance Passion Success
Conclusion
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Thermoplastic laminates can be used in serial production processes for the automotive industry.
Properties of both semi finished material and overmolding material determine part performance.
ULTRASIM® enables fast development of overmolded continuous fiber parts even in crash relevant applications. Hereby strengths of these materials can be used by far better than with standard methods.
Interesting weight and cost results can be reached in automotive seats.
Automotive Solutions Performance Passion Success
The information and data given here are based on our current knowledge and experience. This does not relieve the purchaser of our products from incoming inspection. The information and data do not describe the suitability of the product for a specific application. Composition - and durability statements - as well as any other statements are not to be considered as a warranty. The values contained herein are based on analysis/testing of laboratory test specimens and represent data that fall within the normal range of properties for natural materials, unless stated otherwise. Colorants and additives may alter properties. This information is provided as a service for comparative purposes only and in no way constitutes any product specification or the like. For component design the data contained herein are applicable as guideline only.
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