CompositesWorld
Issue link: https://cw.epubxp.com/i/681810
JUNE 2016 22 CompositesWorld WORK IN PROGRESS Flexural strength & Impact performance improved ICP contends that AFR technology can enable commodity composites, such as discontinuous glass fber-reinforced polypropylene (PP), to perform at levels normally seen only with dramatically more-costly premium materials. In the graph above, application of IM-AFR technology to the same part (while maintaining the same fber-volume fraction of 40%) boosts fexural strength 3.3x (left) and impact performance 5.5x (right) vs. the baseline 40% glass-reinforced LFT PP material, and do so without negatively afecting cost, weight, cycle time or aesthetics. Source | Integrated Composite Products Inc. Performance of Polypropylene with varying Glass Percentages and Lengths Scaling of 100 = Failure Point for 40% LFT Baseline Materials 600 500 400 300 200 100 0 40% Long Fiber W/O ICP Adv. Tech. 40% Long Fiber WITH ICP Adv. Tech. 40% Long Fiber W/O ICP Adv. Tech. 40% Long Fiber WITH ICP Adv. Tech. Flexural Force Scaled 100 100 Impact Force Scaled 600 500 400 300 200 100 0 335 551 as well as with a variety of molding processes (injection, compres- sion, and transfer). Tanks to extensive design of experiments work, the team has learned how to optimize rib sizes and wall thicknesses. It is also able to control which mechanical properties are improved on a part via controlled AFR placement techniques, and by adjusting the size (length, thickness, mesh opening) and formulation of AFR elements. For example, in the case of a standard-duty food bin, ICP has demonstrated how it can easily upgrade performance through selective use of TM-AFRs to meet the needs of a heavy-duty food bin program. Conversely, the company also can convert the same standard-duty food bin into a lighter-duty produce bin merely by adjusting the type, quantity, and position of the AFRs going into the tool — all without altering the tooling or cycle time (reportedly, when AFR loading is automated, little or no time is added to the molding cycle) or delaying the program. Tis allows the molder to use a single toolset to make a variety of products, e.g., 1,000-, 2,000- or 3,000-lb (454-, 907- or 1,361-kg) capacity reusable plastic containers (RCPs), greatly extending tooling functionality. IP protection and commercialization ICP has taken steps to protect its intellectual property. Te compa- ny's frst patent, covering TM- and IM-AFRs, has been published by the US Patent Trade Ofce and is in the fnal stages of active examiner review. Two additional patents, covering advances in