|
|
|
| Plastics making moves in automotive, airline
seating |
| Date: December 6th, 2009 |
| Publication: www.plasticstoday.com |
| Article: Click
Now |
| Download
PDF Version |
| |
By Matt Defosse
Recent discussions make clear that engineering thermoplastics
potentially could shake up the airline and automotive seating
industries, as developments speed ahead in a bid to replace
more metal in these high-volume applications.
The most vivid example was displayed by plastics supplier BASF
at the Fakuma tradeshow last October. The company highlighted
the use of a number of its in the new Opel Insignia OPC passenger
car, to include in the front seats of the vehicle. Opel worked
with Tier One supplier Recaro on the seating.
The seats are made of two polyamides belonging to BASF’s
Ultramid polyamide (PA) range, as well as of the Neopolen expanded
polypropylene (EPP) foam. BASF assisted with its Ultrasim simulation
software in the design of the seat pan, backrest shell and crossbar.
The plastic parts are replacing the steel frames previously
employed. BASF’s work in simulation software extends back
more than a decade, and now it even has a website offering extensive
information, including case studies, on Ultrasim.
The seat pan is molded of Ultramid B3ZG8, a stiff PA6 that ensures
high-energy consumption values. Ultramid B3G10 SI was specified
for the freestanding backrest shell as well as in the crossbar.
The insert for the backrest shell is made of Neopolen P 9225
K (EPP), energy-absorbing foam that also covers edges and serves
as a module carrier for motors and seat components such as the
spinal column support.
Prototypes of the seats were shown back in October 2007 at the
K tradeshow, with the same trio (Opel, Recaro, and BASF) involved.
One company working closely, though not exclusively, with BASF,
specifically of late on development of fiber-reinforced polyethersulfone
(PES) compounds, is PlastiComp (Winona, MN). PlastiComp has
developed from a compounder to become more of a design and manufacturing
expert, able to offer its customers FEM (finite element method)
analysis, Moldflow filling software, parts design and more,
while still also marketing compounds. “We’re not
bound to a specific matrix material nor to a particular process,”
explains Stan Verbraak, business development manager for PlastiComp
Europe GmbH (Steenbergen, The Netherlands).
One of PlastiComp’s customers recently developed airline
seating using one of these PES-based compounds in which those
parts passed the 16G crash test (other seating components not
made of the fiber-reinforced PES did not pass). Airline seating
still largely is metal. If some of the airline developments
eventually move into automotive seating, “It could be
a game changer,” reckons Verbraak.
Verbraak says many of the company’s most recent developments
have been with carbon fiber-reinforced compounds. The price
of these fibers has dropped as supply has increased, making
them a more viable economic option. Also, although glass is
still offered in more tow sizes, carbon fiber suppliers are
expanding their product range.
Carbon fiber is more difficult to work with than glass or aramid,
he notes, as the rovings are more difficult to open and impregnate.
Poor carbon fiber wet-out leaves loose fibers that can float
in a facility and even short circuit electrical systems. “So
you need to get it (the compounding) right,” he notes.
Beyond seating, opportunities could appear in military applications,
sports and leisure products and more; replacement of metal EMI
(electronic magnetic impulse) shielding also is possible.
At the IAA automotive tradeshow in September, Johnson Controls
revealed its new seating concept, the Synergy-Seat, which it
hopes to bring to market in 2012, assuming customers are found.
The seats, slimmer than standard seating so that rear passengers
have about 5cm more legroom, make heavy use of recycled plastics,
especially PP. The amount of PUR foam in the seats has been
reduced and is based on bio-polyols. MPW sat in it and it was
indeed fine, but would need a long trip to pass final judgment
on its comfort. The seats weigh up to 30% less than comparable
current ones, says JC. |
| |
| Back to 2009
Media Reports |
| |
|
About
Us | Complēt
| Pushtrusion®
| D-GMT®
| In-line
Injection
R&D |
Specialty Molding | Technical
Library | Current
News
Technical
Bulletins | Technical
Data | Press
Releases
Media | Career Opportunities
| Contact
© Copyright 2010 PlastiComp, LLC |
| |
|
| |
|
|
