10/14/2013

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IKV: Reactive moulding - Lightweight on a large scale

The project combines the advantages of the liquid impregnation process, which allows the processing of textile preforms, with the benefits of a thermoplastic matrix. For this, the research team is developing a completely automated, highly integrated pro­cess that takes advantage of in-situ polymerisation. By transferring the system to the injection moulding process (in situ injection moulding), it is possible to combine complex fibre preforms with a monomer for large-volume production directly in the injection moulding machine. The IKV research team chose a shin guard as the demonstrator.[image_0]Conventional production processes for FRP parts have a number of disadvantages. For example, until now they have required two separate processes (e. g. for nylon composite sheet: impregnation and moulding). Furthermore, the moulding is restricted to comparatively simple geometries and a limited range of surface finishes. The IKV process aims to eliminate these disadvantages. With the in situ injection moulding process, the textile preform is impregnated with low-viscosity caprolactam monomer, and then reacts by in situ poly­merisation to produce polyamide 6. Requirements for this new pro­cess, apart from an optimised matrix formulation, include customised fibre/sizing systems, a special injection moulding machine technology and, above all, innovative mould, sealing and process engineering.
The shin guard has been chosen to demonstrate the effectiveness of the process. The part consists of a hard protective component made of fibre-reinforced thermoplastic and the flexible component made of a TPE. As a result, the part has high mechanical properties, good impact behaviour, low weight, and high wear comfort. Furthermore, the highly integrated innovative process allows the high-volume production needed for series manufacture. The thermoplastic elastomer is supplied by Kraiburg TPE.The partners in the IKV exhibition project include: ASS Maschinenbau, Clariant, EM-Systeme, Engel, gwk Gesellschaft Wärme Kältetechnik, Hasco Hasenclever, Hennecke, Keller Lufttechnik, Kistler Instrumente, Kraiburg TPE, Lanxess, P-D Interglas Technologies, Piovan, and Schöfer.
On its stand, the IKV will also present acoustic part design, as well as new developments in blow moulding, film extrusion, and rubber technology.IKV will also be represented on the Science Campus in hall 7, where 16 universities, institutess and technical agencies will showcase a wide variety of future-looking technologies. Under the theme "functional integration”, IKV will demonstrate the integration of materials, processes and technologies for the manufacture of high-grade products. They include the projectile injection technique, variothermal mould temperature control and integrated products such as electrically conductive plastic compounds.Hall 14, stand C16

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