StaMax in Automotive Applications: Developments in Thermoplastic

StaMax in Automotive Applications:
Developments in thermoplastic Door Modules
By Bert Claessens
Product Manager STAMAX BV
Contents
- Introduction StaMax® long glass PP
- Why door modules?
- Example of Ford Fiesta door module
- Future developments
STAMAX BV , a SABIC PP Automotive subsidary
Long glass fibre pellet material
12 or 25 mm pellets
20, 30, 40% glass PP
(or 60,70% masterbatch)
STAMAX BV , a SABIC PP Automotive subsidary
Stiffness, strength - Effect of fibre length
Fibre effectivity η
1
Stiffness
0.8
Impact
Strength
0.6
0.4
Injection
moulding
region
0.2
0
0.1
1
SG-PP
10
100
Fibre length (mm)
STAMAX BV , a SABIC PP Automotive subsidary
Typical injection moulded properties
Tensile modulus
(MPa)
Tensile strength
(MPa)
Failure elongation
(%)
Falling dart impact
strength
(J/mm at t=3.2 mm)
Temp.
(°C)
30%
23
80
23
80
7000
5050
109
67
9400
6500
121
75
4000
23
2.3
2.2
2.5
23
-40
6.8
7.6
7.0
8.0
6.8
7.6
40%
testbars
30%
isotropic
65
STAMAX BV , a SABIC PP Automotive subsidary
Typical long glass PP applications
Door
structures
Instrument
carrier
IFEM
Splash
shields
Bumper
beams
STAMAX BV , a SABIC PP Automotive subsidary
Door modules - Why?
Increased number of functions, new car models:
•
•
•
•
•
•
•
•
•
•
•
•
control panel
latch/lock, lock motors
anti theft device
mirror adjustment
crash energy absorption element
window guide
window regulator motor
door handle fixation
arm rest support
vapor seal
speaker
ambient lighting, etc., etc…..
STAMAX BV , a SABIC PP Automotive subsidary
Door modules - Why?
Significant increase in overall quality level of door,
e.g. reliability of window regulator system, no corrosion
related malfunctioning anymore.
Assembly:
Trend in reduction floor space area for car assembly line.
Reduction in stock and stock area.
Cost:
Difficult to prove cost savings:
Extra part introduced.
Foil, sound absorption mats removed.
=> it is quality improvement that reduces "hidden cost"
STAMAX BV , a SABIC PP Automotive subsidary
Metal to Composite
VW-Passat
Brose
Ford Fiesta rear door, StaMax® 30YM240
(source: Ticona)
Weight saving:
50 % lighter than steel
nearly 4 kg per car!
STAMAX BV , a SABIC PP Automotive subsidary
Why long glass PP?
With respect to metal:
- Weight saving
- Corrosion resistance
- More design freedom, e.g. integration possibilities.
- Complex crash energy absorption features (not possible in metal)
With respect to other plastics:
- Excellent stiffness at wide temperature range
- Excellent strength
- High dimensional stability and reproducibility!
- Low thermal expansion
- Excellent resistance to various fluids
- Good flow ability
- Relative low cost
STAMAX BV , a SABIC PP Automotive subsidary
Example - Ford Fiesta rear door module
STAMAX BV , a SABIC PP Automotive subsidary
Typical load cases
Forced entry, 735 N
Arm rest, 1000 N down
Door pull, 1000 N max.
+ Fatigue loads at lower load levels.
STAMAX BV , a SABIC PP Automotive subsidary
Most critical case: Door Pull 1000 N
Sheet Metal
StaMax
39 MPa
20 MPa
317 MPa
Allowable= 65 MPa
=> O.K.
Deflection ca. 6 mm at door grip
STAMAX BV , a SABIC PP Automotive subsidary
Gating variants - examples
3 plate proto mould -> cold runners
Many gating variants studied,
both experiment and calculation,
to achieve best shape and performance
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Flow front, warpage
Filling
Deflection - out of plane
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Warpage - prediction sealing flange
A
CAD
Gate option A
Gate option B
B
6 mm
In general: Direction more or less O.K.
Magnitude of warpage not accurate
STAMAX BV , a SABIC PP Automotive subsidary
Bolt mounting forces
A
2
1
Gate option A
Gate option B
4
3
5
9
6
Mounting forces (N)
100
80
7
8
60
40
B
20
0
-20
1
2
3
4
5
6
7
8
9
-40
-60
STAMAX BV , a SABIC PP Automotive subsidary
Dimension CAD vs. measured - Forward door
One moulding condition, 16 parts, mould not yet corrected.
676.00 676.37 +/- 0.06 (s.d. =0.03)
max/min
range
395.00
394.77 +/- 0.06
371.00
(s.d. =0.03)
(s.d. =0.03)
370.39 +/- 0.05
z
y
x
572.00 572.32 +/- 0.05 (s.d. =0.02)
STAMAX BV , a SABIC PP Automotive subsidary
Dimensions - Influence moulding conditions
Total 35 panels, holding conditions: 0-12 seconds, 0-45 bars.
581.00 580.94 +/- 0.14
Panel weight (g)
415.00
415.33
900
+/- 0.13
850
800
No influence of holding conditions!
0
10 20 30 40 50
Holding pressure (bar)
STAMAX BV , a SABIC PP Automotive subsidary
New developments
Fuel inlet valve
- Still further integration:
=> functional integration
=> structural upgrade
StaMax®
- 2K moulding, e.g. TPE rubber seal
Sarlink®
- Further hybrid material use:
e.g. Dyneema® inserts for crash safety
- Alternative production processes:
e.g. Injection Compression Moulding
STAMAX BV , a SABIC PP Automotive subsidary
Further functional integration
Lock module,
to be integrated
Window rail support + fixing bracket
Metal speaker housing
Electronic cable assy:
Over-moulding =>
Improved cable protection
Window motor
support housing,
axis support
Redesign components for door module!
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Further integration - structural upgrade
Steel
Trim
Inner panel yes or
no reinforced with
continuous fibre
thermoplastics
Current
status
Improved
integration
with trim
Structural inner panel,
plastic outer panel
STAMAX BV , a SABIC PP Automotive subsidary
Injection Compression Moulding
Disadvantage:
- Complex mould, wear at shear edges
Advantages:
- Low pressure process
-> Over moulding cables easier.
- "Weldline-free" moulding easier
-> Better warpage control
- Better "holding pressure" distribution
-> Less sink marks, semi-visual parts
- Somewhat longer fibre length
STAMAX BV , a SABIC PP Automotive subsidary
Conclusions
- Co-operation between Ford, Faurecia and StaMax yielded
successful introduction of composite door modules.
- A module gives quality improvement
- Significant weight saving over metal door module
- Exciting possibilities for further integration in the future.
STAMAX BV , a SABIC PP Automotive subsidary