Download - BASF Polyurethanes Asia Pacific

Automotive
Composite Materials
Breaking the mold with LFI.
BASF has been energetically pursuing the development
of LFI technology for vehicle components
in buses, trucks, special-purpose machinery and
cars since 2006.
BASF Asia Pacific is now celebrating
success with the application of this
technology in China as well. An
important customer here is Yangzi
Motor Decoration Company Ltd.
Long fiber injection (LFI) is used in
this field to reinforce light and strong PU parts with long glass fibers – the
instrument panel carrier material in the new Scania buses, for example. In an
LFI system, glass fibers are cut from a reel and chopped into superfine fibers
that are then mixed with the PU reaction system. The mix is then fed into an
open mold. The mold is closed and the component is formed under pressure,
with the glass fibers and PU system combining to yield an extra-strong composite
material.
Quicker, harder, more durable and ultimately cheaper. Every production
step benefits from the LFI process.
Long-fiber-reinforced PU comes with a host of significant advantages. These
include new design scope for interior and exterior parts. By modifying various
machine parameters, it is even possible to change the material’s mechanical
characteristics in some cases. With the aid of various decorative materials
(PVC, TPO, ASA/PC, to name but a few), it’s possible to adapt the surface to
the application in question. This means appreciable savings in expenditure
and time – firstly, through the use of inexpensive glass fiber filaments, with
reduced waste thanks to optimized distribution by robot. The cutting and preforming
of the glass fiber mats is no longer necessary. And secondly, the
individual components no longer have to be produced in a laborious manual
lamination process. Now all it takes is a single work cycle, even for compo nents
with extra-large surfaces. To this end, an already thermoformed thermoplastic
sheet is laid in the mold, and the polyurethane – in this case Elastoflex ® E – and
finely chopped glass fibers are laid on top. Then the mold is closed, the material
cures, metal reinforcements and fasteners are fitted to the inside, and the
new Scania component is finished. The process couldn’t be faster or more
precise.
Further information: www.scania.com
Contact: Jan Yang, BASF Polyurethanes Specialties, BASF Asia Pacific, Shanghai,
China, e-mail: jan.yang@basf.com
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