High strength, stiffness, and impact properties
c-GFRTP

Overview and Features
レンセン™(c-GFRTP、連続繊維強化複合材料) レンセン™(c-GFRTP、連続繊維強化複合材料)

What is LENCEN™ (c-GFRTP)?

LENCEN™ (c-GFRTP) is a continuous glass fiber reinforced thermoplastic formed by stacking layers of a continuous glass fiber textile with polyamide-66 (PA66) films.

Continuous fiber reinforced thermoplastic is a composite material formed by impregnating glass fiber textiles or similar fabrics with thermoplastic resin, then solidifying to yield a sheet-shaped product, and also known as a composite, organo-sheet or prepreg.
The acronym for Continuous Glass Fiber Reinforced thermoplastic is c-GFRTP (the first c is lowercase), but there are other notations such as GFRTP and GFRP.

LENCEN™

Key features and manufacturing process of LENCEN™(c-GFRTP)

The features and manufacturing process of LENCEN™, prepreg product formed by stacking layers of a continuous glass fiber textile with polyamide-66 (PA66) films, are introduced here.

Light weight and high physical properties

In order to realize further weight reduction of automobiles, we are studying the mechanism of the interfacial strength development of resin and glass fiber, and have developed a technology to improve high strength, high stiffness, and high impact.

We intend to propose this material as a material which may provide collision safety and weight reduction because it has tensile strength and impact properties equal to or greater than those of metals, and may also contribute to improved reliability and fuel efficiency.

Cross-sectional SEM photograph after cutting and high-load polishing

Manufacturing process

LENCEN™ is produced via the following procedure.

1.Layering: Layers of glass fiber fabric are stacked together with resin-film layers.
2.Heating/pressurizing: The layer stack is heated and pressurized in a press, causing the resin to melt.
3.Impregnation: The molten resin soaks through glass fibers.
4.Finally, the product is cooled to solidify the resin, yielding sheet of material ready for molding.

Also, because PA66 are thermoplastic resins, they can be combined with injection molding of materials of similar types (hybrid of composite and injection molding, composite sheet overmolded with injection molding). This allows formation of complex-shaped parts such as ribs and flanges, offering the possibility of cost reductions thanks to improved component rigidity and better integration with neighboring components.

【What is prepreg?】
Prepreg is a term used to refer to sheet of molding material manufactured via the impregnation process described above. The term organo-sheet is also used.
The combination of materials used to produce prepreg may be chosen in many ways. For the resin films, common choices include thermoplastic resins such as polyamide or polypropylene; thermosetting resins may also be used. For the reinforcing fibers, common choices include glass fibers and carbon fibers, which may be woven into continuous fiber textiles or aligned in uni-directional (UD) configurations; non-woven (random) configurations of chopped fibers are also used.

Application Proposal

01

Proposal to EV battery cases

Battery cases in electric vehicles are typically made from metals such as steel or aluminum. The goal of reducing component weight to extend vehicle travel distance suggests the possibility of switching to resin materials, but typical resins cannot offer the required thermal resistance; also, cost reduction is a perennial issue.

Advantages of LENCEN™(c-GFRTP)
1.Lightweight: Specific gravity approximately 1/4 that of steel.
(Specific gravity:  LENCEN™ 1.9 Steel  7.9 Aluminum  2.7)
2.Heat-resistant: No holes appeared in burning tests after 30 minutes at 1000°C.
3.Cost-effective: Cost reduction can be possible through integration or reduction of components
Upper cover: Potential reduction in need for anti-rust paint and thermal insulation.
Lower case: Potential reduction in need for undercover.

レンセン™1000℃×30分の燃焼試験
▲Heat-resistant: No holes appeared in burning tests after 30 minutes at 1000°C.
02

Bumper beam, brake pedal

Metals such as iron and aluminum are used in parts like bumper beams and brake pedals, leaving many possibilities for weight reduction.

These components require materials with excellent strength, stiffness, impact, and durability. We believe that LENCEN™ that combine these characteristics are suitable.

Iron bumper beams require post-processing, such as bending or welding with separate parts, but this material can reduce weight, as well as the number of processes and parts.

レンセン™の強度、剛性、衝撃吸収性、耐久性
▲LENCEN™ has excellent strength, stiffness, impact, and durability.

Please contact us to ask any questions, discuss any concerns, and request samples.

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