TECHNOLOGY

REINFORCEDplastics JANUARY/FEBRUARY 201416 www.reinforcedplastics.com

A collaborative project LIPA

(Lightweight Integrated Process

Application) betweeen a number

of companies is now resulting in

the series production of

lightweight fi bre composite parts.

The project combines fabric-

reinforced thermoplastic

thermoforming with long-fi bre

direct injection moulding.

Tepex fabric-reinforced thermo-

plasticsheets are cut to size and

then pre-heated and then placed

in the mould, where they are

thermoformed and at the same

time provided with moulded-on

ribs, bearing eyes and other

working parts. This is through the

long-fi bre direct injection

moulding process developed

German company Arburg. The

result is a lightweight part of

extremely high strength and

stiff ness. For the production of a

demonstration lever, two pre-cut

fabric-reinforced thermoplastic

sheets of diff erent thicknesses are

gently heated up to thermofor-

ming temperature in synchro-

nism with the moulding cycle of

the machine. A robot equipped

with a vacuum gripper transfers

the blanks into the mould cavity

where they are thermoformed

into a W-shaped profi le. This not

only increases the rigidity of the

lever but also ensures a

full-surface, fi rmly pressed,

positive connection between the

two component sheets. Stiff ening

ribs and an edging of long

fi bre-reinforced plastic are then

injection moulded onto the

sheets. As the temperature of the

sheets is only slightly below the

melting temperature of the base

polymer, a good bond is ensured.

For the same reason, it is also

possible to produce moulded-on

elements (for example, screw

bosses) by injecting through the

sheet without causing any

damage to the fi bre structure in

the moulded part. In order that it

can be connected to a mating

part in a downstream process,

the demonstration lever is

provided with a corresponding

hole during the moulding

operation without adversely

aff ecting the fi bre structure.

The LIPA project initiator is Georg

Kaufmann Formenbau AG, with

LIPA partners being Kistler

Instrumente AG and Krelus

Infrared. Other project partners

include Arburg, Bond Laminates,

FPT Robotik GmbH & Co. KG,

Georg Kaufmann Concept GmbH,

HRS, Lanxess Deutschland GmbH

and SKZ - KFE GmbH.

Georg Kaufmann Formenbau

AG; www.gktool.ch

Collaborative venture yields lightweight composite parts

Cytec launches prepregs

for railway applicationsCytec Industrial Materials is

adding two new products to its

rail portfolio that meet the fi re

requirements of EN45545-2:2013.

Cytec adds that the fi rst, MTM®

348FR, is a versatile curing epoxy

resin prepreg matrix off ering fi re

protection to category HL2. MTM

348FR, in combination with

either glass or carbon fi bres, is

claimed to off er excellent

mechanical performance and is

ideal for the manufacture of

lightweight composite compo-

nents for both interior and

exterior structural and non-struc-

tural applications.

The second, XMTM30, is a

development product produced

from a bio-renewable sustainable

source and meets the require-

ments of category HL3. It is

particularly suitable for the

production of non-structural

interior components. It can be

used in combination with natural

fi bres to create a bio-sustainable

system. Cytec adds that it is

looking for partners and projects

to develop this new technology.

Dr Richard Horn, Rail Market

Manager. said: “The key

advantage of prepreg technology

is that it enables the manufac-

ture of lightweight complex

monolithic sections and

sandwich structures thereby

off ering weight saving and a

reduction in running costs to

the train operator.”

Typical railway interior applica-

tions include wall panels,

window frames, partitions,

archways, fl oors, ceilings,

standbacks, luggage racks,

seats and doors.

Cytec Industrial Materials;

www.cytec.com

MFG develops non-

flammable SMC materialMolded Fiber Glass Industries

(MFG) has introduced a new

proprietary sheet moulding

compound (SMC) material with

non-fl ammable properties.

Known as iNVENTA 616UL, the

material received UL 723

approval from Underwriters

Laboratories earlier this year. UL

723 is recognised as the industry

standard for evaluating surface

burning characteristics of

building materials.

Initially formulated for HVAC

(heating, ventilation, air

conditioning) system compo-

nents, the attributes of iNVENTA

616UL are ideal for many

applications where non-fl amma-

bility is important and greater

than ten square feet of compos-

ites may be required. Newly

mandated safety regulations are

forcing manufacturers in many

industries to retrofi t or redesign

their product components or

housings with fi re retardant

materials. In some cases, making

a material change is a tipping

point to a major redesign that

leverages the natural benefi ts of

fi breglass composites in other

ways - such as parts consolida-

tion, sound level reduction,

corrosion resistance and weight

reduction. This activity is

contributing to the current

robust growth in the composites

industry.

According to MFG director of

Sales Alec Raff a: “It’s becoming

standard now for customers in

many markets to ask for

non-fl ammable and low smoke

formula - heavy trucks, lighting,

and electrical utility parts, for

example..”

Molded Fiber Glass Industries;

www.moldedfi berglass.com

RP0114_Technology News 16 20-01-14 08:38:17