Transcript No Slide Title

FIBERIMTM
New Materials
for Variable Fiber Injection
David Gibala
Andreas Rothacker
New Plastics 2000 Conference
Brussels, Belgium
March 14, 2000
14/03/00
FIBERIMTM
Objectives

14/03/00
Describe Variable Fiber Injection
(VFI) Process
FIBERIMTM
Objectives


14/03/00
Describe Variable Fiber Injection
(VFI) Process
Discuss Benefits and Uses of VFI
FIBERIMTM
Objectives



14/03/00
Describe Variable Fiber Injection
(VFI) Process
Discuss Benefits and Uses of VFI
Demonstrate Broad Range of
Applications and Physical Properties
FIBERIMTM
What is Variable Fiber Injection?


Process to Produce Polyurethane Composites
 Uses Fiberglass Roving
 Chopped to Variable Lengths
 Glass “Injected” into Mixhead
Automated One-Step Delivery of Polyurethane
and Fiberglass
Cannon InterWetTM - Krauss-Maffei LFI-PURTM
14/03/00
FIBERIMTM
Typical VFI Process Schematic
Fiber
Roving
Isocyanate
Metering
Pumps
Robot
Chopper
Polyol
Mixhead
Mold
14/03/00
PU-Fiber
Mix
FIBERIMTM
Simplified Schematic of VFI Mixhead
Glass
Roving
Chopper
Isocyanate
Clean-out
Piston
Chamber
Pour Piston
Polyol
14/03/00
FIBERIMTM
Benefits of Variable Fiber Injection Process

14/03/00
Control of Fiber Length
 Uniform or Distribution of Fiber Lengths
 Ability to Change of Length During Pour
FIBERIMTM
Benefits of Variable Fiber Injection Process
Control of Fiber Length
 Uniform or Distribution of Fiber Lengths
 Ability to Change of Length During Pour
 Integration with Robotics
 Accurate Placement of PU-Fiber Mix
 Ability for Multiple Pour Patterns

14/03/00
FIBERIMTM
Benefits of Variable Fiber Injection Process
Control of Fiber Length
 Uniform or Distribution of Fiber Lengths
 Ability to Change of Length During Pour
 Integration with Robotics
 Accurate Placement of PU-Fiber Mix
 Ability for Multiple Pour Patterns
 Potential for Enhanced Economics
 Lower Cost Fiberglass Roving
 Reduced Labor and Handling
 Waste Reduction

14/03/00
FIBERIMTM
Applications and Properties of FIBERIMTM
Produced with VFI Process

14/03/00
Broad Range of Properties and Applications
Are Possible:
 Versatility of Polyurethane Chemistry
 Unique Features of VFI Process
FIBERIMTM
Applications and Properties of FIBERIMTM
Produced with VFI Process

Broad Range of Properties and Applications
Are Possible:
 Versatility of Polyurethane Chemistry
 Unique Features of VFI Process
SPG’s from 0.4 - 1.6+
 Glass Content to >50% by Weight

14/03/00
FIBERIMTM
Applications and Properties of FIBERIMTM
Produced with VFI Process

14/03/00
Current and Potential Applications
Seat Pans
Sun Shades
Door Panels
Package Trays
Truck Box Panels
FIBERIMTM
Case 1:
14/03/00
LD-SRIM Door Panel
FIBERIMTM
Table 1 - Physical Properties
LD-SRIM Door Panel:
FIBERIMTM vs. Traditional Technology
Process
Fiber Length
FIBERIMTM
Traditional
50
50
50
Mat
Mat
0.63
0.65
0.63
0.62
0.66
19
22
28
16
23
(mm)
Specific Gravity
Percent Glass
Flexural Modulus
1646 2050 3324 1605 2176
(MPa)
Tensile Strength
(MPa)
14/03/00
15
19
37
16
23
FIBERIMTM
Case 2: High Glass-High Density Composite
14/03/00
FIBERIMTM
Table 2 - Physical Properties
High Density Composite:
FIBERIMTM vs. Traditional Technology
Sample
1
2
FIBERIMTM
Process
Glass Length
3
Traditional
12.5/25*
25
Mat
Specific Gravity
1.3
1.6
1.2
Percent Glass
38
55
38
6740
9650
4600
98
209
85
(mm)
Flexural Modulus
(MPa)
Tensile Strength
(MPa)
* 12.5mm/35mm - 2:1 Ratio
14/03/00
FIBERIMTM
Summary

Describe Variable Fiber Injection
Process



14/03/00
Conventional PU Metering Equipment
Modified Mixhead
One-Step PU-Fiberglass Mixing
FIBERIMTM
Summary


Describe Variable Fiber Injection
Process
Discuss Benefits and Uses of VFI


14/03/00
High Fiber Content and Control
Lower Cost Potential
FIBERIMTM
Summary



Describe Variable Fiber Injection Process
Discuss Benefits and Uses of VFI
Demonstrate Broad Range of Applications
and Properties



14/03/00
Low to High Density
Wide Glass Content Range
Diverse Application Requirements
FIBERIMTM
Acknowledgements
Co-Author:
Andreas Rothacker
Numerous Huntsman
Polyurethanes Colleagues
14/03/00