Toray Company recently developed a hybrid injection molding technology that allows carbon fiber reinforced unidirectional tape (UD tape) to be molded in a single process and deposited in the injection molding mold; under suitable process conditions, the process It is possible to manufacture parts with the same performance and cost as steel parts, but the weight is reduced by 20%.
Toray calls this newly developed technology direct tape insert injection molding. Compared with other hybrid molding technologies in which UD tape is inserted into the mold for injection molding, this technology does not require a direct pre-molding process, and can directly complete molding and deposition in a single process.
By placing the UD tape composed of continuous fibers in the correct position, this technology helps to combine rigidity, strength and high productivity. This technology is the world's first molding technology that can use UD tape to perform insert molding to create 3D shapes without the need for a pre-molding process.
This technology only needs to stick the UD tape on each side of the injection molded product, which can increase the strength and elasticity of the product several times. Carbon fiber reinforced plastic (CFRP) usually has excellent properties, but tends to have a higher price. This technology can also promote CFRP to reduce costs.
The new technology is expected to be used in the manufacture of various parts, including electric car battery boxes, car bumpers, car door anti-collision beams, roof frames, power tools, and housings for electrical and electronic equipment.
Toray's UD tapes are usually based on polyamide 6 (PA6) or polyphenylene sulfide (PPS) matrix. However, the company is also committed to developing tapes based on high heat resistance polyether ether ketone (PEEK), and hopes to add UD tapes to its product line to improve its compatibility with other resins used for injection molding (such as polycarbonate PC ) Adhesion.
At present, Toray's goal is to make the mass production of UD tapes reach a scale of several hundred tons per year, and to increase the output of injection-molded pellets dozens of times. The company is looking for multiple solutions, including the use of facilities in the western region.