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Technical Center, Applied Development Team Working with
Syddansk Universitet, Odense March 9th
Plastic Raw Material Day
www.kopla.com
Long Fiber Material DevelopmentJohnny Bjarnholt-Olsen
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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.
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� LFT (Long Fiber Reinforced Thermoplastic)� LFT (Long Fiber Reinforced Thermoplastic)
KOPLA long fiber reinforced thermoplastics (LFRT or LFT)
It comes from pultrusion process as below picture and it has much better mechanical properties and toughness than short fiber reinforced material. Pellet length is usually 9mm to 12mm and roving fiber (non-broken fiber, usually 20%-60%) is impregnated in melted polymer.
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� LFT (Long Fiber Reinforced Thermoplastic)� LFT (Long Fiber Reinforced Thermoplastic)
■ LFT Feature
: Stiffness & Toughness
� High stiffness / high temperature
� Toughness & impact strength
� Low Temperature
� High creep resistance vs. std. GF
� Excellent dimensional stability & low warpage
� Outstanding fatigue performance
� Good surface appearance
� High productivity & cost competitiveness
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� LFT Sub-Replacement Development� LFT Sub-Replacement Development
Advantages PP LFR vs. PA LFR:• Lower price• Lower Density• Conditioning not required
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www.themegallery.comLONG-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 RangeOur 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
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� Long Fiber Development� Long Fiber Development
Runner & Sprue Designfor Less Fiber Breakage
Runner & Sprue Designfor Less Fiber Breakage
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� Long Fiber Development� Long Fiber Development
Low Compression Screwfor less fiber breakage
Nozzle Size Optimizationfor less fiber breakge
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� Long Fiber Development� Long Fiber Development
Stiffness & Strength Variationthrough Gate Position
Estimate Fiber Breakage Level
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� Long Fiber Development� Long Fiber Development
Enhance weld line strength
Weld Line Location by CAE
Weld line
Hole
Flow Direction
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�GM M2XX Passenger Airbag Housing�GM 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%
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�Structural Analysis Support�Structural Analysis Support 12
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�Injection Molding Analysis Support�Injection Molding Analysis Support
Valve open time : 2.0sec, Reference
2cavity
Detail View
Flow Animation
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�Material Data�Material Data
Test Item Method UnitCurrent 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
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�Safety Belt Spool�Safety 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
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� CAE Support� CAE Support 16
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�Material Data�Material Data
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
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�Panorama Sunroof Frame�Panorama 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
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� CAE Support� CAE Support
Hot runner valve type system apply
Flow animation
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�Material Data�Material Data
Test Item Method UnitPA6-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
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�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
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■ 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
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■ 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
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� CAE Support� CAE Support
Compare gate type
Modal Analysis
Harmonic Analysis
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�Material Data�Material Data
Test Item Method UnitCurrent 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
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Technical Center, Applied Development Team Working with
Questions?
Please visit our websiteswww.kopla.comwww.biesterfeld-plastic.se
Biesterfeld Nordic DKJohnny Bjarnholt-Olsen
E-mail: [email protected].: +45 26226381
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