Kingfa worked very closely with German system supplier Brose Fahrzeugteile to develop its new continuous fiber reinforced material, called KingPly, to fulfil the high requirements set by Brose development. Brose designed the lightweight door module carrier with considerable weight saving targets while not sacrificing any performance requirements.
Brose even managed to increase the functional integration. This succeeded in a weight saving of about 35% compared to a standard injection moulding door module carrier and reduced the car weight of the 4 door model Ford Focus by more than 1 kg compared to a PP-LGF 30 door module carrier. Compared to a standard metal door concept without plastic carrier, this composite design could reduce the car weight by more than 5kg.
With its new composite materials based on UD layers, Kingfa advances into new areas of lightweight design. The thin single layers made of UD tapes, called KingStrong, are used to manufacture custom made semi-finished products in the form of sheets under the brand name KingPly for the customer, which are finetuned exactly to the application and its requirements. In the case of the door module, a very thin but strong multi-layer material is composed to give the part stiffness and strength.
The door module has many requirements: Stiffness, strength, NVH, acoustics and also sealing, as the carrier is on the division line between dry and wet within the door structure. The chosen material is using PP matrix and continuous glass fiber as reinforcement. The sheets are cut by Kingfa to the exact dimensions needed in the injection moulding tool, so that no cutting and waste is happening at the customer’s production.
Martin Klocke, Vice General Manager Automotive Business at Kingfa Sci.&Tech. (Europe) GmbH, the European subsidiary located in Wiesbaden explains:
“Now, even more efficient parts can be designed and manufactured using UD layers, which enable highly custom-made and optimized materials. They can be used even better to implement the lightweight requirements of the future than commonly used similar materials based on woven fibres“
For automotive and beyond
Peng Xiao, General Manager at Guangzhou Kingfa Carbon Fiber Materials Development says:
“Our newly developed thermoplastic composite materials have proven Kingfa’s innovative capacity and we hope to even better support our customers in their lightweight projects. To achieve this, we invested heavily in the design and construction of our own in-house technology and manufacturing. The whole production setup was optimised such that we are ready to tackle high volume mass production. This is proven by this successful mass production project by Brose for Ford.”,
Kingfa currently offers a portfolio of UD tapes, random mats and organic sheets mainly based on glass fiber and different thermoplastic matrix materials. For KingPly organic sheets, PP and PA6 are offered for mainly automotive purposes, whereas for KingStrong UD tapes a larger variety with PP, PA6, ABS and HDPE offer also applications outside of automotive.
Especially the innovative mix of organic sheets in conjunction with UD tapes as local reinforcements by Kingfa will ensure that a recyclable, affordable lightweight future is within reach for many applications.
Industries: Automotive & Road Transportation