SPE Library
The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.
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Conference Proceedings
Renewable Resource-Based Composites for the Automotive Industry
The incorporation of renewable resources in composite materials is a
viable means to reduce environmental impact and support sustainability
efforts in the composites industry. This paper will focus on unsaturatedpolyester
resins prepared from renewable resources and their use in
composite materials. Applications of these resins in the automotive
industry will be described including a comparison of properties and
performance vs. typical petroleum-based resins.
Development of Injection Moldable Composites Utilizing Annually Renewable Natural Fibers
In order to advance the commercialization of natural fiber reinforced
plastics for automotive use a partnership was formed between
academia natural fiber processor material supplier and OEM.
This partnership improved the communication along the supply chain
and resulted in optimized material properties to meet OEM specifications
and application part performance. Several products have been
developed that meet current material specifications offer significant
weight savings over conventional mineral- and glass-reinforced composites
and are competitively priced.
Economical Preform Production for Conventional & Natural Fiber Composites
This paper presents an independent cost analysis for a novel slurrybased
preform technology in order to understand its potential benefits
across a range of component and reinforcement scenarios. Specifically
the economics for small medium and large automotive composites
reinforced with glass carbon and natural fibers through the use of
manual sprayup automated P-4 and slurry preforming are examined
and compared through technical cost analysis. The molding economics
of SMC RTM and SRIM are also addressed in detail.
Renewably Sourced Engineering Polymers for High-Performance End-Use Applications
External trends have continued to drive end users in consumer
and industrial applications to seek renewably sourced and sustainable
solutions to use in more and more demanding applications. To meet
this need a portfolio of renewably sourced engineering materials
was developed. The products are designed to provide performance
and functionality equivalent to or better than today’s petroleumbased
materials while reducing the environmental footprint.
The portfolio includes glass-reinforced thermoplastic grades for
high strength and stiffness.
Improved Matrix Materials for High-Performance Carbon Fiber Aromatic Thermosetting Copolyester
The use of new aromatic thermosetting copolyester (ATSP) is described
and compared to the best available epoxies for high performance
composites. ATSP oligomers display liquid crystalline behavior which was
identified using optical microscopy with cross-polarizers.ATSP tailored to
have a liquid crystalline structure has reduced stresses at the fiber/matrix
interface and better thermal fatigue resistance compared to epoxy.
Low Temperature Cure Polyurethane Adhesive for Primerless" Composite Bonding "
A new polyurethane adhesive has been developed that provides
excellent adhesion to SMC HSU and RTM without surface preparation
and requiring only a room-temperature cure or greatly reduced postbake
temperatures. This presentation will review where such an
adhesive will find application its general chemistry and supporting data.
Bentley Motors Develops Unique Directional Carbon Fibre Preforming Process for Chassis Rails
Details are presented on an automated process for manufacturing
net-shape charges for compression moulding using a spray-deposition
technique. The novel process uses a resin-spray technique and magnetic
fibre to position and hold fibres onto the tool face. The process is
intended for producing structural components using discontinuous
bundles for medium-volume applications.
Reducing Setup Costs: Tooling Force Prediction in Resin Transfer Moulding (RTM) & Compression RTM
Mould tools used for processes such as RTM and compression RTM
must withstand significant forces generated by the fluid resin and the
fibrous reinforcement. Prediction of these forces will allow for optimizations
in setup costs and time and maximize the usage of the capabilities
of peripheral equipment (such as presses). SimLCM is being developed
at the University of Auckland as a simulation package with the capability
to predict clamping forces and stress distributions during complete
moulding cycles for RTM and CRTM.
Pushtrusion™ Direct In-Line (D-LFT) Compounding Technology versus LFT Pellets & GMT Sheet
PlastiComp’s direct in-line (D-LFT) compounding process provides
processors of fiber-reinforced thermoplastics a simple and affordable
alternative to pre-compounded pellets and GMT sheet while yielding
equivalent and in some cases slightly higher mechanical properties.
This paper summarizes a comparative study of the properties of
D-LFT vs. traditional LFT pellets in an injection-molding process as
well as D-LFT vs. GMT sheet in a compression-molding process.
A Formulation Study of Long Fiber Thermoplastic Polypropylene (Part 1): The Effects of Coupling Agent Type & Properties
The relationship between the resin and fiber properties in polypropylene
long fiber thermoplastics is further analyzed in the second part of
this work. The properties of the maleic anhydride grafted polypropylene
additives (coupling agents) are studied and correlations between
the maleic anhydride content melt flow and base polymer used is
presented. Polypropylene long fiber thermoplastics pellets were
compounded with various coupling agents. The materials were then
molded and tested. The results of the study are presented.
High Performance Reinforcement: A Pathway to Density Reduction while Maintaining Physical Properties of Polyolefin Composites
To achieve significant part weight reductions of 15-20% Milliken
Chemical's high performance reinforcing (HPR) additive may be an
excellent choice for the replacement of talc and other mineral fillers in
polypropylene composites. For instance vs. talc HPR will typically
provide comparable or superior performance with only about one-third
of conventional talc concentrations. Furthermore these improvements
may be realized without any detrimental effects on aesthetic properties.
Innovative PPS Blow-Molded Air Duct for Turbocharged Diesel Engine
A new patented in-mold assembly process forms an optimized
assembly using a combination of blow molding and injection molding
for a turbo-charged diesel charge air duct. The process incorporates
a 15%-GF-reinforced blow-molding grade and a 30%-GF-reinforced
injection molding grade of polyphenylene sulfide. PPS was the
material of choice due to its superior heat and chemical resistance.
Advances in Thermoplastic Composites Using CBT
The use of cyclic-polybutylene terephthalate (C-PBT) for manufacturing
high-performance composites is taking on new roles. Advances in
injection molding RTM molding pultrusion and composite tooling are
benefiting from the use C-PBT thermoplastic resins leading to the
development of new C-PBT technologies and applications.
Alternative Methods to Enable the Powder Priming of SMC
Previous work has shown that the newly developed SMC systems are
powder-primer ready in straight-through operations. However after an
extended stoppage in the operation – such as July shutdown – the
success of the powder application depends on the severity of temperature
ramp in the oven. To overcome this issue alternative methods are
proposed such as 4 min. of preheating in the oven at 180°C or 3 min.
of IR exposure.
The Influence of SMC Formulation Inner Panel Thickness & Bond Stand-Offs on Bond-Line Read-Through Severity
Two experiments designed to understand the relationship between
material and process factors and bond-line read-through (BLRT)
severity will be discussed. Regression analyses of the data collected in
these experiments were able to establish relationships between the
experimental factors and BLRT severity with at least 80% correlation.
Flexibility in the Direct Strand Moulding Compound (D-SMC) Process
In order to improve quality issues as well as to establish an integrated
and continuous process for compression-moulded parts a direct
processing technology has been developed. This presentation should
demonstrate the flexibility of the new direct-SMC technology in terms
of use of alternative and new raw materials and formulations.
Recent Advances in Class A Polyurethane Long Fiber Injection (LFI) Composites
Recent advances in related polyurethane chemistry have increased
the commercial viability of the long fiber injection (LFI) process for
producing very-large composite parts such as entry-door skins truck
body and spa panels and recreational boat hulls. These advances
enable the LFI process to achieve previously unattainable extended
gel times on an open hot mold retain a relatively short demold time
and form defect-free surfaces that can lead to the Class A surfaces
required for large automotive body panels.
Composite Power-Train Components: Reducing Warranty Costs & Improving Part Quality
Sheet-molding compound has been used in underhood applications
and is extending its reach to drivetrain components. This presentation
will show how vehicle manufacturers have reduced costs and improved
quality through product designs that eliminate hardware enhance
capability and improve system performance.
Automotive Composites Consortium Structural Composite Underbody
The Automotive Composites Consortium Focal Project 4 (ACC FP4) is
a joint program between GM Ford and Chrysler to develop structural
automotive components from composite materials. Part of this project
is a structural composite underbody capable of carrying crash loads.
Phase 2 of the project involves a full design of the underbody including
design for durability and feasible component manufacturing and vehicle
assembly scenarios.
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