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Fig. 1: Injection molding machine equipped with "D-LFT system"
Mitsubishi Heavy Industries Plastics Technology Corporation (Headquarters: Nagoya City) announced on March 2, 2015 that it will develop a "D-LFT system" for compounding, metering, and injection molding of high-strength parts by maintaining the fiber length in fiberglass-reinforced resin. (See Figure 1, LFT: Direct Long Fiber reinforced Thermoplastics, Long Fiber Reinforced Thermoplastics). It is characterized by the separate input of resin (polypropylene, PP) and glass fiber (Figure 2). Compared with the use of glass fiber-containing particles, it is expected to reduce the material cost by 25% and reduce the cost of the molded product by 11%. The purpose of the aim is to replace large steel parts such as automobile body parts.
The glass fiber-reinforced long fiber particles have a length of 8 to 11 mm, and the length of the fiber is the same. However, during the kneading process before the resin is injected, the glass fiber is usually broken, and the fiber after molding is changed to about 2 mm. Mitsubishi Heavy Industries Plastics Co., Ltd. has previously developed an "LFT screw" that ensures a fiber length of about 5 mm by improving the shape and control of the screw for kneading. At the same time, the company developed a process for feeding glass fibers with a length of 9 mm halfway while mixing a glass fiber-free resin with an LFT screw. The length of the fiber remaining in the molded product reaches about 5mm, ensuring the same strength as the original, and "sufficient to replace the steel components" (Mr. Kubota Koji, Director of Mitsubishi Heavy Industries Plastics Technology Co., Ltd.). In addition, users can also reduce material costs by purchasing glass fibers and resins separately.
Since the glass fibers are bundled, if the glass fibers are not sufficiently unraveled during kneading, the glass fibers are unevenly distributed and sufficient strength cannot be secured (FIG. 3). In order to develop hardware and control software that allows fiberglass to break without breaking, developers spend a lot of time thinking about it. At the time of development, we cooperated with fiber manufacturer Nippon Electric Glass. In addition, the two companies will jointly build related systems, provide formula information and technical support to users who have introduced the D-LFT series, help users to select resin materials and fibers, and determine the amount of additives that are compatible with the amount of fibers.
Figure 2: Material input port. Resin (PP) and glass fiber (length 9mm) were put in separately.
Figure 3: Molded products after development and after development. The presence of solidified glass fibers in the right-side molded product ensures sufficient strength.
The D-LFT system is to be used in combination with Mitsubishi Heavy Industries' injection molding machine "MEII+ Series" with a clamping force of 550tf or more, and "emII" (clamping force of 1050tf ~ 3500tf) for medium to large injection molding machines. According to reports, the price is 1.5 to 1.6 times that of a normal screw, but the price is lower than that of a model made by a German manufacturer that can use long fibers. (Reporter: Kizaki Kentaro)
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