This paper analyses the lightweight potential for automotive applications obtained by injection molded, long-glass-fiber reinforced integral foams using breathing mold technology. Extensive investigations of two material systems, PP-LGF and PA6-LGF, were carried out using both, a chemical blowing agent and a physical blowing agent. During injection of a gasloaded melt into a cold mold, integral foam occurs consisting of a compact skin and a foamed core over entire cavity, regardless of the complexity of the molded component. The integral foam design, which can be conceived as a sandwich structure, helps to save material in the neutral axis area and maintains a distance between load-bearing, compact (unfoamed) skin layers. This sandwich structure leads to a high bending stiffness at a low surface weight, which is required by many automotive applications, especially for large-area covering elements (such as door panels, spare wheel wells, seat shells and backrests, underbody assemblies or instrument panel supports). The experiments showed that, at a constant surface weight, long-glass-fiber reinforced integral foams have a significantly higher bending stiffness than compact components, due to their higher area moment of inertia after expansion achieved through precision mold opening. The area moment of inertia and with this the bending stiffness is increased with the third power of the wall thickness. For that reason, a small increase in wall thickness leads to a significant higher flexural rigidity. Compared to the compact reference, an increase of the flexural rigidity for all investigated combinations of material and blowing agent could be realized. At a constant surface weight, the bending stiffness in these experiments could be increased by up to 600 %. An instrumented impact penetration test, applied for PA6-LGF50, showed growing energy absorption and a Charpy impact bending test, applied for PPLGF30, showed nearly constant behavior with increasing density reduction. The delay time before mold opening influences the thickness of the solid skin. As seen with PP-LGF30, through thicker skins the bending and the impact strength seemed to increase, while the tensile properties seemed to slightly decrease.


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    Titel :

    Fiber-reinforced integral foams for the production of lightweight truck components


    Beteiligte:
    Roch, A. (Autor:in) / Kehret, L. (Autor:in) / Huber, T. (Autor:in) / Henning, F. (Autor:in) / Elsner, P. (Autor:in)


    Erscheinungsdatum :

    2015


    Format / Umfang :

    16 Seiten, Bilder, Tabellen, Quellen


    Anmerkungen:

    (engl. Version 369-384)



    Medientyp :

    Aufsatz (Konferenz)


    Format :

    Print


    Sprache :

    Englisch




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