Seat Pan Opel Astra OPC - SPE Automotive · Seat Pan Opel Astra OPC Calvin Nichols, BASF Corporation . Automotive Solutions Performance Passion Success Continuous Fiber Reinforcement

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

3

UD-Tapes CF

UD-Tapes GF


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

4

BASF and TenCate: Strategic Alliance for Thermoplastic Automotive Composites


Measurement Process

Draping / Molding

Material

Part

Integrative Simulation ULTRASIM® for Continous Fiber Reinforced Plastics

5

BASF approach: full ULTRASIM® prediction and design level for continuous fiber reinforcement


Material Characterization Laminates and Tapes

Tensile Test Orientation

Testing Speed

(Wallthickness)

Humidity

3 Point Bending

Puncture Test

Compression Test

Sheartest

Adhesion of Ribs

Draping

6

Drapiereigenschaften IVW, Kaiserslautern


Which Type of Semi Finished Material?

7

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


Example: Prototype-Seat Backrest with overmolded Tape Reinforcement

8

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


Automated Tapelaying Available Processes

9

Moving Head with laser welding fixation

Moving Table with ultrasonic fixation


Consolidation of Tapes Microscopy und Micro-CT

10

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


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


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

12


Drop Tower Test Influence of Overmolding Material

13

PA GF Resin - Standard PA GF Resin “Optimized”


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


Example: Serial Front Seat Pan Opel Astra OPC

Adam Opel AG SeaTcon AG/ SedisTec UG Reinert Kunststofftechnik

Maier Formenbau


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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


Integration of Relevant Process Steps

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In-Mold Forming Injection Molding Mechanics

Integrative Simulation with ULTRASIM®


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

18


In-Mold-Forming and Overmolding

mold closing side mold injection side

laminate in open mold

IR heater

19 Cycle time 70 sec


Micro CT Testing

20


Component Testing

m = 25 kg v = 5 - 9 m/s

21


Seat Testing

22

Quelle: SedisTec


Wall thickness 1 mm in laminate 45% weight saving Function integration Cost balance

Serial Application in Opel Astra OPC


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.


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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Seat Pan Opel Astra OPC - SPE Automotive · Seat Pan Opel Astra OPC Calvin Nichols, BASF Corporation . Automotive Solutions Performance Passion Success Continuous Fiber Reinforcement