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Long Fiber Composites - SINTEF Fiber Composites Colin Rooney ... Short Fiber Long Fiber. Fiber...

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  • Long Fiber Composites

    Colin RooneyThanks to Karl Hoppe

  • Presentation Overview

    Very Long Fiber (VLF) Intro

    Property comparisons

    Metal replacement

    Case studies

  • Standard Compounding Process

    Cooling

    Extruder

    Blender

    Pelletizer

    Classifier

    Raw Materials Finished Product

  • VLF Manufacturing Process

    Fibers

    Extruder

    Pelletizer

  • Pellet Comparison

    Fiber Length~ 1-2 mm 12 mm

    Short Fiber Long Fiber

  • Fiber Retention

    PA 66 + 60% VLFSeat Belt Tensioner Housings

  • Improved impact

    Safer impact mode

    Reduced warpage

    Improved creep resistance

    Advantages of Long Fiber

  • Drop Impact Test

    Incr

    easi

    ng lo

    ad

    ShortFiberNylon

    LongFiberNylon

  • End User: Red Wing ShoesMaterial: VLFPolyurethaneApplied Technology:impact modification

    Benefits of stampedmetal replacement

    Molded net shape Thermal insulation Non-permanent deformation

    Application: Safety Toe Cap

  • End User: Harken, Inc.Material: VLF nylon 6,10Applied Technology:deep, rich, pre-colored blackextra UV protection

    Benefits of stainlesssteel replacement

    Cost reductioneliminate machining

    Prohibit corrosion from sea water

    Application: Side Block Plates

  • General guidelines:1. General purpose screw OK (low compression preferred)2. Reduce shear: low back pressure and rpms3. Reverse barrel profile

    preferred:

    Molding Considerations

  • Additives

    Your color Your wayImpact enhancementFlame retardantsWear & lubricityHeat stabilizersNano particlesUV resistanceConductivityTaggantsSpheresAnti-stat

    Polymers

    PEEKPPSPBTTPUPPPAPC

    Long Cut dry blends

    Combining Technologies

  • Fiber Retention

  • Property Comparisons

  • Strength/Impact Advantage

    short LONG

    Tensile Strength

    13,000psi

    17,500psi

    Flexural Modulus

    1.00x106 psi

    1.20x106 psi

    Notched Izod

    2.0ft*lb/in

    5.0ft*lb/in

    HDT @ 264

    285F

    310F

    incr

    easi

    ng

    STI

    FFN

    ES

    S

    increasing TOUGHNESS

    Sho

    rt fib

    er re

    info

    rced

    Impact Modified

    VLFLong Fiber

    Polypropylene with 40% glass fiber

  • Nylon 6/6 40 Glass Fiber%

  • End User: Honda, GM, Toyota

    Material: VLF Polypropylene

    Benefits of replacingshort glass nylon

    Cost reduction Weight reduction Designed for the environment

    more commonly recycled

    Application: Auto Shifter Base

  • 01234567

    Not

    ched

    Izod

    Impa

    ct

    (ft*lb

    /in)

    PP PA 6/6 RTPU PPA

    50% Long Glass Compounds

    73F-40F

    Low Temperature Impact

  • Metal Replacement

  • Reduce cost

    Design freedom

    Environmental concerns

    Corrosion and chemical resistance

    Sound and vibration dampening

    Metal Replacement Objectives

  • End User: Demco-DethmersMaterial: VLF nylon 6/6

    Benefits of die castmetal replacement

    Cost reductioneliminate paintingeliminate machining

    Prohibit Rust Increased functionality

    molded in fluid sight window

    Application: Brake Cylinder

  • ZAMAK

    ZAMAK alloys are the designer's first choice when considering die casting. Z for Zink (zinc) A for Aluminum MA for magnesium K for Kupfer (copper)

    ZAMAK 3: This is the most widely used general purpose zinc die casting alloy

  • Instantaneous Properties at 23 C

    Zamak 3 60% VLF PA6/6

    Specific Gravity 6.6 1.7

    Tensile Strength (MPa) 282 275

    Flexural Modulus (GPa) 85.5 19.3

  • End User: Vertex FastenersMaterial: VLF Nylon

    Benefits ofmetal replacement

    Molded net shape Lighter Faster

    Application: Fastening Tool

  • Summary

    Increase impact, keep stiffness

    Combine technologies

    Take advantage of plastic design

  • Application...Shield

  • Application...Pistol Body

  • Application...Textile Wheel

  • Application...Cycle Support

  • LadenburgGermany

  • Ladenburg

    Equipment4....VLF Lines

    2.... 58 mm Mega Compounders

    2.....40 mm Mega Compounders

  • Ladenburg

    VLF Materials PolypropyleneNylon 6, 66

    Glass % 30,40,50 & 60Compounds High Volume

    PolypropyleneNylons

  • 60% VLF Concentrate Neat polypropylene, other Blend at the press Big parts

    VLF Concentrate Masterbatch

  • Platform: 2009 Dodge Journeyletdown: 20% long glass PP

    VLF PP Concentrate Market Success

    Benefits of usingVLF PP

    Designed for the environmentEasily recyclable, use of regrindLightweight

    6.6 lbs/part

  • Long Fiber CompositesPresentation OverviewStandard Compounding ProcessVLF Manufacturing ProcessPellet ComparisonFiber RetentionAdvantages of Long FiberDrop Impact TestApplication: Safety Toe CapApplication: Side Block PlatesMolding ConsiderationsCombining TechnologiesFiber RetentionProperty ComparisonsStrength/Impact AdvantageNylon 6/6 40 Glass Fiber%Application: Auto Shifter BaseLow Temperature ImpactMetal ReplacementMetal Replacement ObjectivesApplication: Brake CylinderZAMAKInstantaneous Properties at 23 CApplication: Fastening ToolSummaryApplication...ShieldApplication...Pistol BodyApplication...Textile WheelApplication...Cycle SupportLadenburgGermanyLadenburgLadenburgVLF Concentrate MasterbatchVLF PP Concentrate Market SuccessSlide Number 35

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