As early as August, SGL Carbon received a long-term order from Koller Kunststofftechnik to produce new carbon fiber profiles for the windshields of BMW Group's future mass models.
This profile is a particularly soft fiber tow, pre-impregnated with various sizes of thermoplastic resin. They will be processed by SGL Carbon at its factory in Incles, Austria based on its own 50k carbon fiber, and then processed by Koller's injection molding experts to form skeleton plastic components. This composite part will replace the previous steel windshield. The production of carbon fiber profiles will begin in the rest of 2020, and will be gradually increased in the next few years in preparation for the BMW Group to launch models.
In vehicles, the windshield is the connecting element between the roof frames, and therefore has an important stabilizing function. Carbon fiber profiles increase the stiffness and crash safety required by the components. At the same time, they help to significantly reduce the weight of the roof, thereby supporting driving dynamics. The injection molding process can also achieve particularly complex and material-efficient structures. In the BMW Group's model, this innovative component concept will reduce the weight by 40% compared to traditional steel component designs, while creating important space for cable ducts and sensors.
The production of carbon fiber profiles is also particularly suitable for materials and process efficiency in mass production. The profile is composed of several smaller fiber bundles (the so-called rods) and is manufactured using modern continuous pultrusion. During product and process development, ensuring that material losses in the production process are almost completely avoided is a major goal.
Sebastian Grasser, head of the automotive division of the SGL Carbon Composites-Fibers and Materials business unit, explained: "At SGL Carbon, we are already engaged in thermoplastics for injection molding. The development of carbon fiber profiles has been around for some time. This development work has now begun to pay off. Due to its many advantages and competitive costs, we have seen great progress. The technology may also be used in other automotive projects. "
Max Koller, CEO of Kohler Group, confirmed: “Innovative lightweight structures with hybrid designs have developed into a strategically decisive concept for Koller Group OEM customers. SGL Carbon`s high-level material expertise and Koller Kunststofftechnik and Koller Formenbau’s process knowledge has laid the foundation for a bright future with innovative light-weight construction technology. With this order, the BMW Group has confirmed its confidence in the successful cooperation between SGL and Kohler; we are particularly pleased with this."
The Kohler Group is a globally operating technology company with factories in Europe and China and the North American Free Trade Zone. Kohler Group mainly develops and manufactures lightweight structures, tools and series components for the automotive industry.