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thermoplastic
and the processing parameters to scaled, geometrically complex components. An essential prerequisite for the implementation of this process is an appropriate, complex handling system comprising clamping, heating and tracking systems. The handling system must allow the fibres to be kept stretched during the entire handling process, thus ensuring timeoptimized handling of the organic sheet. Potential applications include stiff, geometrically complex, large-scale components used in the transport sector. The process is particularly suitable for the near-net-shape, main-cyclesynchronous manufacture of structural components with improved energy absorption properties and greater weightsaving potential. the manufacturer, because production using these systems is energy-efficient and highly automated, and therefore suitable for mass production. Furthermore, the shorter process chain promotes overall process robustness, and the consistent use of thermoplastic materials based on a single polymer type enables inexpensive recycling. The end user receives a highly functional product combining many different functional elements. This offers a host of benefits in terms of product use, fields of application and effective product utilization. n
More information: www.jacobplastics.com Acknowledgements The authors would like to thank the German Ministry of Education and Research Affairs (BMBF) for funding the SpriForm and FIT-Hybrid research projects. The author is grateful to Neue Materialien Fürth, Lehrstuhl für Kunststofftechnik (Erlangen), Institut für Verbundwerkstoffe (Kaiserslautern), Bond Laminates, Lanxess, KraussMaffei, Schaumform, Siebenwurst and Audi for supporting this work. References Müller, T.: Herstellung von hybriden Leichtbau-Verbundrohren mit integrierten Funktionselementen durch Fluidinjektionstechnik (FIT-Hybrid). Beitrag zum Jahrbuch BMBF Rahmenprogramm WING, 2008, Berlin Schuck, M.: Herstellung funktionsintegrierter leichter CompositeCrashbauteile durch Verfahrenskombination. IVW-Kolloquium, 2010, Kaiserslautern Schuck, M.: Kompatibilitätsprinzipien beim Montagespritzgießen, Dissertation, 2009, Erlangen Ehrenstein, G.W.: FaserverbundKunststoffe. 2. Auflage, Carl Hanser Verlag, 2006, München Ehrenstein, G.W., Wacker, M., Obermann, Ch.: Thermoplastische Matrix eröffnet neue Möglichkeiten. Kunststoffe 92 (2002) 6, S. 78 - 81

By using injection moulding, none of the component edges are left open as they can be fully overmoulded. Furthermore, by optimizing the organic-sheet flat projection along with optimum adaptation to the component processing, an off-tool component can be manufactured. A downstream separation (e.g. cutting) process to manufacture the component is not required.

The process successfully implemented on the first samples was transferred to an application-oriented demonstrator (see Figure 10).

Here, a side impact beam was used. The injected rib structure prevents the profile from opening inopportunely under stress or in the event of failure and transmits the forces directly to the underlying structures. As with the FIT-Hybrid process, SpriForm makes it possible to integrate metal inserts which facilitate force transmission into attached metal structural components (e.g. a car body). Currently, the bond between the thermoplastic and insert is created using a form-closure. In principle, however, it is also possible to add a metal insert in a post-process. This demonstrator (see Figure 10) is used as an example to demonstrate the complex process chain. The type of demonstrator selected should enable the transfer of both the identified and analyzed properties

jec composites magazine / No66 July - August 2011

Fig. 10: SpriForm – leading-edge technology

Conclusions

The technologies described here have significant commercial potential because the innovations presented can be used in many of the market segments – including the automotive, medical-technology, sports and leisure, and aerospace industries – which require products that are lightweight yet meet considerable mechanical property demands. Thanks to their functional integration potential, these processes can fulfil many different demands, whether on the part of the end user (e.g. attractive design and additional comfort) or the manufacturer (e.g. reduced costs), thus replacing existing components. A further benefit is the economical production of new products with unique features. There are real economic benefits for

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JEC COMPOSITES MAGAZINE - Issue #66 - July/August 2011

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