pps proceeding - Abstract Preview
pps proceeding
Symposium: Injection Molding & Molds
Keynote Presentation
 
 

Innovative process technology for endless fiber reinforced thermoplastic composites with integrated functionalities by injection molding

Muehlbacher Mathias (1), Altstaedt Volker (1)*

(1) Neue Materialien Bayreuth GmbH - Beyreuth - Germany

A novel production process for thermoplastic high-performance fiber composites has been developed, which is capable to fulfill automotive requirements in terms of lightweight design, compatible costs and short cycle times of approximately one minute. The process is based on 2D or 3D preforms made from endless fiber reinforced unidirectional thermoplastic composites, known as UD-tapes. The stacked UD-tapes (2D or 3D) are heated to a temperature above the melting point of the thermoplastic matrix to consolidate the individual layers into a compact composite structure. For the thermally sensitive UD tapes, it has proved suitable to use uniform heating in the circulating air oven, which does not stress the material and can be easily controlled. Subsequently, the heated tapes are transported into a mold by a handling system where they are in-situ consolidated. The combination of endless fiber-reinforced composite structures with injection molding in one step permits both additional functions to be integrated, for example improved acoustic properties, and local mechanical reinforcement. For the development of the above-mentioned technology to manufacture thermoplastic fiber composite structures, the research institution Neue Materialien Bayreuth GmbH, Bayreuth, Germany has installed an automated manufacturing cell for large-scale thermoplastic composite parts in its technical center. Key features are a HK paternoster oven, a handling system and an ENGEL vertical 2,500 t injection-compression molding machine. The principle of the vertical clamping unit was chosen to allow gravity to be used for part insertion. As results will be shown the automated and integrated process for PP-GF parts within cycle times of 70 s, influence of different production parameters to processing and achievable mechanical performances.