Product category:
Moulding materials
News Release from: LNP Engineering Plastics Europe | Subject: Verton MFX composite
Edited by the Manufacturingtalk Editorial
Team on 16 April 2003
Injection moulded composite used in door
module
Long glass fibre reinforced polypropylene composite provides high performance cost-reducing foundation for new Mazda 6 and future door modules.
Verton MFX long glass fibre reinforced polypropylene composite from LNP Engineering Plastics, a GE Plastics company, is central to the 'first of its type' door module carrier in the all new Mazda 6 series mid-size car launched in Europe in January 2003 Unlike earlier modules made from steel-stamped parts or press moulded glass-mat reinforced thermoplastics, the Mazda's module carrier features a low viscosity, high flow Verton MFX polypropylene composite with a high crystalline structure that can be injection compression moulded or injection moulded
This article was originally published on Manufacturingtalk on 4 Dec 2002 at 8.00am (UK)
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As a result, the module carrier can be moulded to thinner wall sections and is much stronger, lighter, is highly recyclable and allows the integration of functions, to deliver lower production costs.
The Mazda door module, which combines parts and integrates functions, holds the speakers, latch assembly, door lock actuator and glass window regulator, and provides sound damping and security improvement, as well as acting as a seal against the elements.
"A new material and injection moulding technique were developed for this large part.
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The technique reduces the pressure and shear on the long glass fibres compared to conventional injection moulding processes," explains Otto de Bont, European Marketing Manager for LNP.
"As a result, the glass fibres are significantly longer after moulding than with conventional injection moulding.
The longer glass fibre length means higher impact strength," he says.
In addition, the process delivers low moulded-in stress for exceptional dimensional control.
Further complementing the Mazda module carrier, the Verton MFX composite provides improved high-temperature fatigue resistance compared to similar nylon-based composites.
It also gives a resin-rich, high quality surface finish.
Another advantage of the proprietary Verton MFX polypropylene composite is its extremely low viscosity, which increases flow by over 30% compared to conventional long glass fibre reinforced polypropylene.
As well as allowing thinner moulding sections, low viscosity makes part integration possible.
Moreover, integration and fewer parts reduces processing costs.
In turn they lead to lower cost for the trim panel and reduced assembly time with fewer handling problems because assembly is less precision dependent.
Mazda, a leading automobile manufacturer headquartered in Hiroshima, Japan, intends to use the composite and new processing technology to develop other functional modules for use in new models.
The company, founded in 1920, produces cars and trucks in 16 countries and sells them in more than 130 countries worldwide.
According to Paul Willems, Industrial Design Leader for LNP in Europe: "The next step to driving increased design flexibility and production economies will be development of the Super Integrated Door Module that integrates the structural components as well as the functional ones.
This will include the window regulator rails and gear housing, enclosure for electronics and also the base for a full length armrest support.
"This type of integration is very new and the Mazda development provides the bridge between what has been achieved to date and what will be accomplished in the future," he says.
In taking the next step, development of the Super Integrated Door Module, materials will need to satisfy new as well as higher performance criteria including high mechanical strength at temperatures ranging from -40 to 80degC.
During the opening/closing of the window there are very high forces exerted on the carrier which are increased by the weight of the traditional steel window regulator mechanism.
When closed there is a permanent pressure on the system which at high temperatures presents a problem in respect of dimensional stability as temperatures can build up to 80-90degC within the door module.
LNP is confident that it has the materials solution to satisfy all performance criteria including that for the window regulator system.
In this component the standard solution is to use a metal carrier and a plastic sliding part together with large quantities of lubricant.
LNP can provide an all plastics solution where the complete regulator system is made of plastics and no external lubricant is required.
This solution involves moulding the rails in Verton MFX composite as an integrated part of the door module, while the slides are moulded in a special Lubricomp, an internally lubricated compound based on acetal and teflon, that achieves self-lubrication.
The resin-rich, higher-quality surface finish of the Verton polypropylene composite ensures that the slides operate smoothly on the integrated rails.
An additional benefit is that the near class A surface finish achieved with Verton allows for its use in applications exposed to the interior of the car.
Integrating visible components such as the door handle housing or vent outlets into the door module reduces the complexity and cost of the trim panel, which in turn lowers the total cost of the door assembly.
Headquartered in Exton, Pennsylvania, USA, LNP Engineering Plastics, a GE Plastics Company, is a global leader in the custom compounding of engineering thermoplastics.
The company operates nine manufacturing plants throughout the USA, Mexico, Europe, Asia Pacific and South America.
In Europe, LNP Engineering Plastics is headquartered in Raamsdonksveer, The Netherlands, from where, supported by manufacturing plants at Fosses, France, Thornaby-on-Tees, UK and Pontirolo, Italy, it serves customers' needs throughout the region.
LNP is known for innovative, value-added products and ultra-fast development of viable solutions for its customers.
The LNP product line includes a wide range of specialty compounds for information technology, automotive, health care, industrial and consumer applications.
GE Plastics is the world's leading producer of engineering thermoplastics, with major production facilities worldwide.
GE Plastics materials, including LEXAN polycarbonate resin, are used in a wide variety of applications such as CDs, automobile parts, computer housings, cookware, outdoor signage, cell phones, bullet resistant shielding and building materials.
The company is also a global distributor of resins through GE Polymerland, and of sheet, film, rod and tube products through GE Polymershapes and GE Structured Products.
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