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PUR LFI Technology and Honeycomb Sandwich, puropreg™ systems |
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Glass fibre enforced PU composites - honeycomb low density parts |
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LFI- PU is a highly automated process for the production of fibre enforced PU composites. Despite the traditional SRIM process various fibre materials and the PU components are fed in the mixing head in an one step process.
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The PU-fibre-mix is poured in an open mould which is closed after pouring. It is possible to have a finished surface by inserting preformed textiles and cover foils in the mould. The process allows the production of door panels, package trays and load floors / covers for a wide variety of applications.
The LFI-process enables the manufacturer to produce parts in two different technologies:
» The standard process for parts with thin walled profiles like instrument or door panels and
» a process for low density composites in honeycomb technology for package trays and load floors.
The cavities are filled with a robot mounted system which enables the manufacturer to vary the fibre content and amount of raw material while pouring. Fibre contents with a ratio between 10 and 50 % of the total mixing head output are possible. The fibre processing unit also allows the variation of the average fibre length between 12,5 and 100 mm. Changes to the fibre processing unit allow the usage of natural, carbon, aramid and other fibres. At the moment the usage of glass fibres is dominating the applications. The mixing head is able to process compact and cellular polyurethane systems.
These are the economy advantages of the LFI-process compared to the SRIM-process:
» Usage of cheap fibre rovings,
» Reduced fibre waste,
» One-step process,
but there are also technical advantages:
» homogeneous dispensation of fibres and PU-material
» robot controlled pouring allows different fibre-PU-densities in different areas of the cavity
» wetting of the fibres while pouring
» small profiles possible
» no fibre orientation
» high durability values
» low thermal distortion
» direct lamination in an one-step process
Our pilot production is equipped with a Krauss-Maffei RIM-Star 40 high pressure metering unit, a robot mounted LFI-unit and a mould press for customer production tests.
Honeycomb composite parts - structure and advantages
» Sandwich structure containing glass fibre enforced PU layers and recycled paper honeycomb
» Stiff, self supporting structure ideal for package trays, load covers, luggage load covers, automotive interior panels
» Density reduction up to 60% through honeycomb structure
» high temperature/ heat durability
» high dimensional stability
At the moment we are developing LFI-Systems based on renewable raw materials and natural fibres. With this systems it will be possible to fulfil the OEM demands for parts with an renewable raw material content higher than 50 %.
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Example of use:
» LFI Mixing Head
» 3D part PUR 181-2
» LFI parcel shelve Audi (Honeycomb Sandwich)
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