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Summary: An instrument panel that is produced by a long fiber glass material that is produced by inline compounding of a polymer matrix material with the glass fibers from rovings being dispersed into a separate twin screw processing unit.
Weight Savings: 35% compared to steel.
Cost Savings: 40% compared to GMT.
Most Innovative Feature: Reduction of energy consumption by means of an application-oriented composition of materials perfectly adapted to the needs of instrument panels using in-line compounding of a polymer matrix material and introduction into a separate twin screw processing unit for the introduction and dispersing of glass fibers coming from the rovings.
Other Innovative Features: Innovative development of two separate machines for the production of fiber-reinforced compounds. Separation of the compounding process from the fiber introduction into the polymers. Ability to compound by high sheer energy and integration of the glass fibers into the plastic matrix without sheer energy.
Forming Process: Compression molding
First time process used?: Yes
Previous Process Used: GMT - Compression molding
Tooling Innovations: Compression toolings that are capable of molding complex component geometries have been developed, such as used before by injection molding. Furthermore, the integration of an airbag steel sheet has been solved.
New Material Developments: An LFT-D-ILC compound adapted to the component parameters has been developed
Weight Savings: Savings in weight compared with steel: approx. 35%
Direct Cost Savings: Estimated material cost savings compared with GMT: approx. 40%.
Indirect Cost Savings: Unknown
Direct Consumer Benefit: Unknown
Translates to other Vehicles?: Yes, the compounding and compression technology can be used for other applications.
Safety Benefits: Unknown
Environmental Benefits: The LFT-D-ILC material can be recycled and directly integrated into the manufacturing process of the new compound.
Additional Info: By means of the high degree of freedom of the direct processing regarding the selection of the material, the components are directly adapted to the specific needs of the corresponding application. The LFT-D-ILC application grants the potential of further developments - that means that besides glass fibers, also other reinforcing materials, such as natural or carbon fibers can be introduced in matrix materials, such as PP, ASA, ASB, Polyamides. Compared with semi-finished products, additional ecological and economical advantages result in savings of energy (the material has to heated only once), reduction of pollution (minimized transports and logistics). By means of a metal component substitution, the use of the material considerably reduces the weight of the vehicles which can increase their load and save fossil fuels.
