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Use of Continuous Fiber Reinforced Engineering
Plastics: The Seat Pan of the Opel Astra OPC
Jrg Schnorr, BASF SE, Dr. Ralf Langendorf, Adam Opel AG, Rsselsheim, Jordan Kurikov, BASF SE, Ludwigshafen
VDI International Congress
Plastics in Automotive Engineering
Mannheim, 13.-14. Mrz 2013
New Applications in Automotive with

Fiber Reinforced Engineering Plastics
Semi-structural parts
Ultramid
Short fibers
Structural parts
Ultramid Structure
Long fibers
Polyamide with continuous fibers

(Tape/Laminate + Overmolding)
Developments supported by simulation tool ULTRASIM

Continuous Fiber Reinforcement

of Injection Molded Parts
Types of Semi Finished Products
Thermoplastic
laminate
Organosheet
(picture IVW)
Heating
One Shot Draping

and Overmolding
Reinforced plastic
molding
UD
Tape
Pultruded Tape
fully impregnated
Laying of tapes
(picture AFPT)
Reinforcer
Reinforced
plastic molding
Potential of continuous fiber reinforced plastics

Carbon vs. glass fibers --- Stiffness vs. Strength
140
All materials 50 Vol.-% fiber content

120
UD-Tapes CF
[GPa]
Stiffness
Stiffness [GPa]
100
80
Al
60
Laminates 0/90 CF
Mg
40
Source: Fiberforge
20
UD-Tapes GF
PA-GF50
Laminates 0/90 GF
PA-GF30
0
0
200
400
600
800
1000
1200
1400
1600
1800
Strength [MPa]
Strength
[MPa]
BASF and TenCate: Strategic Alliance for

Thermoplastic Automotive Composites
Joint development and production of
thermoplastic composites:
UD-tapes and laminates
BASF: Know-how in research, production
and formulation of thermoplastic resins
TenCate Advanced Composites:
Expertise in composite manufacturing
Advanced tapes and laminates
For structural automotive parts
(car body, chassis)
Focus on mass production
Integrative Simulation ULTRASIM

for Continous Fiber Reinforced Plastics
Process
Measurement
Draping / Molding
Material
Part
BASF approach: full ULTRASIM
prediction and design level for
continuous fiber reinforcement
Material Characterization for ULTRASIM

Laminates and Tapes
Tensile Test
Orientation
Testing Speed
(Wallthickness)
Humidity
3 Point Bending
Puncture Test
Compression Test
Sheartest
Adhesion of Ribs
Draping
Drapiereigenschaften
IVW, Kaiserslautern
Ultrasim Helps to Optimize the Design of

Plastic Parts
ULTRASIM
Material modelling Integrative Simulation
Anisotropic
Nonlinear
Strain-rate sensitive
Tension-compression asymmetric
Failure modeling
CAE Methods +
Mathematical Optimization
Process simulation
Mechanical simulation
Mathematical optimization
(parameter, shape, topology)
Calculate the part right
Calculate the right part
Ultrasim Predicts Energy Absorption

Post Failure Behaviour
Force
36
Simulation
30
24
18
12
Experiment
6
0
0
Ultramid Structure
10
20
30
40
50
60
70
80
Way
Which Type of Semi Finished Material?

Tapes
Parts with areas of highest local
anisotropic load distribution
e.g. front seat backrests
Laminates
predominantly closed areas, mechanical
load rather evenly distributed
e.g. seat pans, rear seat backrests,
vehicle floors
10
Example: Prototype-Seat Backrest with

overmolded Tape Reinforcement
Injection
molded PA6
UD-Fiber
reinforcement
Overmolded in
injection molding
process
UD- Fiber reinforcement in high loaded zones

Injection molding material in zones of medium load and functional integration
11
Automated Tapelaying
Available Processes
Moving Table
with ultrasonic fixation
Moving Head
with laser welding fixation
12
Consolidation of Tapes
Microscopy und Micro-CT
glass fibers
before Consolidation
matrix: PA6 Ultramid
after Consolidation
6-layers: 0/90/0/0/90/0
thickness 0,25mm each
60 weight-% glass fibers
13
Component Test and Validation

Dynamic Test, 5.0 m/s Impactor Speed
CAE
Break between bolts in both

CAE and Test
After Test
14
Drop Tower Test

Influence of Fiber Length
Test Temperature 23C
700
PA6 GF50 23C
Ultramid
PA6 LGF40
23C
Ultramid
Structure
Ultramid
+ Reinforcer
PA6 CFRT
23C
600
Energy [J]
500
400
300
200
100
0
0
10
20
30
40
50
60
70
Time [ms]
15
Drop Tower Test

Influence of Overmolding Material
Ultramid 1
Ultramid 2
specific developed
impact modified grade
Ultramid 2
Ultramid 1
16
Further Potential in Vehicles

Structural
Inserts (A-, B-,
C-Pillar, Roof
Frame)
Roof Cross
Member
Cross Car
Beam
Crash
Extensions
Fire Wall
Battery
Integration
Frontend
Structural
Floor
Structures for doors

and hatches,
even online
paintable
17
Example:
Serial Front Seat Pan Opel Astra OPC
18
Example:
Adam Opel AG
SeaTcon AG/
SedisTec UG
Reinert
Kunststofftechnik
Maier Formenbau
19

Thermoplastic laminate based on
Ultramid PA6 and glass fibers
Overmolding material Ultramid

PA6 short glass fiber material
20
Ultrasim for Composites

Integration of Relevant Process Steps
In-Mold Forming
Mechanics
Injection Molding
Integrative Simulation with ULTRASIM

21
Optimization of Heating Parameters
Influence parameters:
Material properties (absorption,
reflection, thermoconductivity etc.)
Type of emitter
Emitter control (power profile)
Distance, time
Trials at Krelus Infrared
22
In-Mold-Forming and Overmolding
mold closing side
IR heater
laminate in open mold
mold injection side
Cycle time 70 sec

23
Micro CT Testing
24
Component Testing
m = 25 kg
v = 5 - 9 m/s
25
Seat Testing
Quelle: SedisTec
26
Serial Application in Opel Astra OPC

Wall thickness 1 mm
in laminate
45% weight saving
Function integration
Cost balance
27
Conclusion
Thermoplastic laminates can be used in serial production

processes for the automotive industry.
Properties of both semi finished material and overmolding

material determine part performance.
ULTRASIM enables fast development of overmolded

continuous fiber parts even in crash relevant applications.
Hereby strengths of these materials can be used by far better
than with standard methods.
Interesting weight and cost results can be reached in

automotive seats.
28
Feedback
die nahezu
perfekten,
18-fach
einstellbaren
Schalensitze
http://www.automotor-undsport.de/fahrberichte/
opel-astra-opcflitzlicht-gewitter-aufder-nordschleife5035812.html
download am
21.11.2012
29
Future Outlook
Design Freedom with New Materials
30
The information and data given here are based on our current knowledge and experience. This does not relieve the
purchaser of our products from incoming inspection. The information and data do not describe the suitability of the
product for a specific application. Composition - and durability statements - as well as any other statements are not to
be considered as a warranty.
The values contained herein are based on analysis/testing of laboratory test specimens and represent data that fall
within the normal range of properties for natural materials, unless stated otherwise. Colorants and additives may alter
properties.
This information is provided as a service for comparative purposes only and in no way constitutes any product
specification or the like. For component design the data contained herein are applicable as guideline only.
31

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Use of Continuous Fiber Reinforced Engineering

Plastics: The Seat Pan of the Opel Astra OPC

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

New Applications in Automotive with

Polyamide with continuous fibers

Developments supported by simulation tool ULTRASIM

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Continuous Fiber Reinforcement

One Shot Draping

VDI International Congress

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Potential of continuous fiber reinforced plastics

All materials 50 Vol.-% fiber content

VDI International Congress

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

BASF and TenCate: Strategic Alliance for

VDI International Congress

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Integrative Simulation ULTRASIM

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Material Characterization for ULTRASIM

VDI International Congress

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Ultrasim Helps to Optimize the Design of

Calculate the part right

VDI International Congress

Calculate the right part

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Ultrasim Predicts Energy Absorption

VDI International Congress

Mannheim, 13.-14. Mrz 2013

Which Type of Semi Finished Material?

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Example: Prototype-Seat Backrest with

UD- Fiber reinforcement in high loaded zones

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

matrix: PA6 Ultramid

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Component Test and Validation

Break between bolts in both

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Drop Tower Test

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013

Drop Tower Test

VDI International Congress

Plastics in Automotive Engineering

Mannheim, 13.-14. Mrz 2013