Thermoplastic OvermoldedThermoplastic Overmolded

Continuous Fiber StructuresContinuous Fiber Structures

September 15, 2011September 15, 2011

KippKipp GrummGrumm

BASF Engineering PlasticsBASF Engineering Plastics

AmitAmit KulkarniKulkarni

FaureciaFaurecia Automotive SeatingAutomotive Seating

Thermoplastic Overmolded Continuous Fiber Structures

VIDEO REAR CRASH SLED TEST

Outline

� What is Continuous Fiber Overmolding?

� What are the advantages of this technology?

� How can this technology be utilized?

• These structures are made by placing continuous fiber (glass or carbon) composite parts into an injection molding tool

• The composite part is then overmoldedwith thermoplastic to form structural or part-integration features

• The finished part can be removed from

the mold and is ready for use.

Thermoplastic Overmolded Continuous Fiber StructuresWhat are these structures?

Overmolded Woven Continuous Fiber Laptop CaseCourtesy Performance Materials Corporation

Thermoplastic Overmolded Continuous Fiber StructuresKey Properties of Continuous Fiber Materials

• Lightweight and Cost Efficient

• High Strength and Stiffness

• High Energy Absorption

• Fast Manufacturing Cycle Times

• Environmental Benefits

Thermoplastic Overmolded Continuous Fiber StructuresAre these structures in commercial applications today?

Audi A7 Front End ModuleLaptop Case

Thermoplastic Overmolded Continuous Fiber StructuresFuture application designs…

• Front seat back structure development with Faurecia and BASF• Other proprietary automotive development projects underway

• Continuous Fiber Tape Manufacturing

• Thermoforming Process Steps• Cut Tape• Kit Sheets• Heat and Consolidate Sheets• Thermoform• Trim (Waterjet or Router Cut)

• Preform blanks can be also be cut from preconsolidated sheets

Continuous Fiber Insert Manufacturing ProcessThermoforming

Continuous Fiber Insert Manufacturing ProcessQuality Control Checking

• Mass Checks for Correct Layers• Dimensional Checks (CMM, Laser Scan, etc)• Microscopy Analysis• µCT Scanning

CFRT Visible Light Microscopy CFRT Fiber µCT Scan

Continuous Fiber Insert Manufacturing Work Cell StudyWork Cell Setup

The various stations show process from tape to final formed part

• Tapes assembled to from kit or sheet (sheet is shown above)• Consolidation station compresses tapes together• Stamping station cuts out preform shape• Robot loads preform into heater, then into molding station

Overmolded Continuous Fiber StructuresManufacturing Process

• Video of Minco molding trial

Technology Development

Material Interaction

Study materials, process

conditions & surface treatments

to optimize adhesion and

develop design guidelines6 Layer

Laminate

Ultramid TG7S

Adhesion Interface

New FEA Methods

Learn and apply new

simulation methods for

laminate analysis.

Ability to model each

layer of laminate

Material Models

Develop accurate material

model for continuous fiber

laminate

Laminate Characterization

Physical Testing

Prove model accuracy

through correlation to

physical testing

Rear Impact,Cargo

Retention, etc.

Overmolded Plastic Adhesion to Continuous Fiber InsertsOptimized Strength Through Testing

• T-shaped coupons: PA6 overmolded to CFRT base• Measured force required to separate PA6 from CFRT• Comparisons can be made between various parameters:

200

250

300

350

400

450

Te

ns

ile

Lo

ad

, lb

s.

Ultramid® TG7S Ultramid® XA 3232

Resin

Ultramid® XA 3232 Adhesion to CFRT

Flame NoOverflow No Flame 1x Overflow

Ultramid® CompoSIT Adhesion to CFRT

Ultramid® CompoSIT

Overmolded Composite CAE Tools

CAE Tools were developed to accurately model the behavior of the composite materials

Single Ply Fiber Tested and Correlated Multiple Ply Sheet Sheets Overmolded with PA6

VIDEOVIDEO

Overmolded Composite CAE Tools

~ 39 mm~ 3.4 kNCAE

~ 41 mm~ 3.3 kNTest

Disp.Force (N)Load

900

~ 55 mm

~ 54 mm

Disp.

~ 3.0 kN

~ 2.8 kN

Force (N)

CAE

Test

Load

450

FEA Reaction Force Matched Test Failure Force

Component Level Testing and CAE Correlation - Side Beam from Seat Back

VIDEOVIDEO VIDEO

Application Example:

Overmolded Continous Fiber Inserts in Faurecia/BASF Seating Project

The goal of this project was to develop a composite seat back to replace the current steel structure

Rigorous Testing and CAE Correlation

• Material coupon level testing and correlation

• Component level testing and correlation

• System level testing and correlation

Application Example:

Continuous Fiber Inserts in Faurecia/BASF Composite Seating Project

VIDEO

VIDEO

Summary: Benefits of Overmolded Continuous Fiber Inserts

� Strong

� Lightweight

� Design Flexibilty

� Component Integration

� Where can you use this technology?