Center console
Lightweight construction with carbon fiber-reinforced plastics
JEC Award 2016
New carbon fiber-reinforced type series
AKRO-PLASTIC GmbH has found a solution for recycling dry carbon fiber fabrics that have not yet come into contact with a polymer matrix and incorporating them into a polymer melt to create added value.
According to the supplier, AKRO-PLASTIC's new range of carbon fiber-reinforced grades, known as "ICF", combines high strength with low density. The compounds can therefore be equipped with up to 40 percent carbon fiber. The aim of the new product line is to achieve a significant weight reduction, particularly in load-bearing components. The electrical shielding and good thermal conductivity make the carbon fiber-reinforced compounds particularly suitable for applications such as activated carbon filters, brackets for control units or center consoles.
The comparison in the table shows that a polyamide reinforced with 15 % carbon fibers, AKROMID® B3 ICF 15 black (5026), has the same modulus of elasticity as a 30 % glass fiber-reinforced PA 6. The approximately 20 % lower flexural strength is offset by a density advantage of over 12 %. With higher degrees of reinforcement, there is a clear advantage of up to 42 % in stiffness with only 12 % lower flexural strength. The weight advantage is a considerable 22 %.
Properties | Unit | AKROMID® B3 ICF 15 | AKROMID® b3 GF 30 | AKROMID® B3 ICF 40 | AKROMID® B3 GF 60 |
|---|---|---|---|---|---|
Train E module | MPa | 11.00 | 10.300 | 30.000 | 21.000 |
Flexural strength | MPa | 210 | 270 | 320 | 370 |
Density | g/cm³ | 1,19 | 1,36 | 1,31 | 1,7 |
Density advantage ICF | % | 12,50 | 12,50 | 22,90 | 22,90 |
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Together with the companies PME Fluidtec GmbH, Ettenheim, Batz S. Cooperation, Spain, and Moldetipo, Portugal, AKRO-PLASTIC has produced a clutch pedal made of AKROMID® B3 ICF 15 black (5026). This material is a 15% carbon fibre-reinforced polyamide 6 that has been optimized for use with water injection technology (WIT). WIT is a process in which the mold is first filled with the polymer melt and then the core material is pressed out of the cavity with water.
Compared to the standard material PA 6 GF 30, this pedal has a breaking strength increased by 100 N to 1,100 N with a 25 % higher stiffness. The weight of the pedal was reduced by 10 %.
The judges of the 16th SPE Awards awarded the complete component, i.e. the bearing block with pedals, 1st prize in the Powertrain category.
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Another highlight of the "ICF" applications is a center console. Made from PA 6.6 GF 30, it had a weight of 1,680 g. With a 10 % ICF-reinforced PA 6.6, AKROMID® A3 ICF 10 black (5117), the weight could be reduced to 1,460 g with comparable rigidity.
The JEC Group judges considered this to be worthy of nomination. They presented the center console with an Innovation Award 2016.