FiberForm Perfect combination of thermoforming and injection molding

Transcription

1 Engineering Passion Seite 1 FiberForm Perfect combination of thermoforming and injection molding

2 Seite 2 New technologies for sustainable lightweight molding KraussMaffei development focus on Megatrends CellForm (Mucell) Foamed parts FiberForm IMM with organo sheets RTM Carbon Fiber with PUR IMC Injection molding compounder PA and Carbon Fiber + Mucell

3 Seite 3 Lightweight portfolio covers the entire range of requirements Schematic lightweight technology portfolio RPM IMM RTM Long Fiber Injection FiberForm Injection Molding Compounder Short glass fiber injection molding Increasing mechanical properties Increasing cost efficiency

4 Components complexity mechanical properties part costs Seite 4 Fiber Composite materials offer a wide spectrum Fiber length vs. Product properties unidirectional Compression molding Fabric Injection molding Direct Fiber Fiber Mat Unreinforced Short Fiber Long Fiber GMT quasi Fiber length in the component

5 Components complexity Seite 5 Textile Reinforced parts with functional integration Combination of injection molding and thermoforming high low Injection molding Thermoforming of textiles Combination of both methods leads to: High strength and stiffness High design freedom High functional integration High degree of automation Short cycle times low high Achievable stiffness, strength, Energy absorption capacity

6 Seite 6 Combination of Injection Molding and Thermoforming Process chain reduction Standard two step process Handling Heating Handling Thermoforming Handling Cutting Handling Injection Molding Handling Deposit Reduced and integrated process steps Handling Heating Handling Master forming and back injection Handling Deposit FiberForm technology

7 Seite 7 Cost efficient production in an one-stage-process FiberForm schematic process description Organo sheet intake 2. Organo sheet heating 3. Transfer into injection mold 4. Thermoforming 5. Injection molding 6. Final part removal 3 5 4

8 Seite 8 Thermoplastic laminates offer many opportunities Materials and set-up Composite sheet based on a thermoplastic matrix Reinforcement is a woven fabric or an unidirectional fabric (UD-Tape) Local or continuous fiber reinforcement Various thermoplastic matrix systems (PP, PA, PPS, PEI, PEEK, ) Different fibrous reinforcements (glass, carbon, aramid or mixed forms) optimized design for application is possible (fiber orientation, layer structure) Source: Bond-Laminates GmbH

9 Engineering Passion Page 9 Application examples

10 Seite 10 Application: Technology part K2010, similar to side impact beam ( TAT ) by AUDI ~ 55 sec cycle time, ~ 590 g weight Innovation: Transformation to thermoplastic with given construction space Process symbiosis of thermoforming and injection molding Back injection with consolidated composite laminates in one step Benefit: Lightweight parts > -20% compared to steel Plastic parts with high impact strength Parts ready for assembly directly after demolding

11 Seite 11 Concept for the K-Show 2013 Hollow profile Local reinforcement Functional integration fasteners

12 Seite 12 Concept for the K-Show 2013 Hollow profile Local reinforcement Functional integration fasteners

13 Seite 13 Composites on Injection Molding Machines FiberForm production cell and partners

14 Seite 14 Airbag housing 50% weight reduction through FiberForm CX FiberForm Application: PP/GF30 with PP-Organosheet Cycle time: < 40s Innovation: LRX as TWIN Z Multiple kinematics Scales for monitoring the constancy of the shot weight, integrated in MC6 IR-oven control integrated in MC6 Blending of high concentrated PP/LGF60 Compact production cell (-25% of area) BluePower Servo Drive Partner: Takata, Siebenwurst, Bond Laminates, Borealis, Motan-Colortronic

15 Seite 15 Application example - Marker binding for tour skiing MARKER Kingpin Development with the S&W GmbH Functional integration via 3 hot runners (Needle valve) Forming Organo sheet Injection molded edge surrounding 1mm wide

16 Seite 16 Application example - Connection of two organo sheets Audi A6 Infotainment carrier Part information Production cell: CX Injection molding material: PA6 GF30 Organo sheet: PA6 GF Cycle time: < 60s Weight: 325g Approx. 50% savings in weight compared to steel part Partners

17 Seite 17 KraussMaffei Technologies long-term experience with continuous fiber-reinforced FVK Technology carrier TAT Airbag housing Takata SpriForm cross beam Frontend with organic sheet in the upper belt door knot A second fully automated production cell is available for customer projects!

18 Seite 18 Vielen Dank für Ihre Aufmerksamkeit Stefan Fenske Technology manager FiberForm & IMC KraussMaffei Technologies GmbH Krauss-Maffei-Straße München Germany Telefon Mobil +49 (0) (0) stefan.fenske@kraussmaffei.com

19 Seite 19 Vielen Dank für Ihre Aufmerksamkeit Mesut Cetin Project and Technology Manager Lightweight Design KraussMaffei Automation GmbH Möslstraße Oberding Germany Telefon Mobil +49 (0) (0)