The project Lite2Duro is researching ways to increase sustainability and energy efficiency in the processing of thermoset plastics. Within a broad consortium, three important process-related obstacles are investigated, simulation methods are further developed, and the solutions are demonstrated in two industry-related applications.
The first step is the development of an active cavity balancing system which enables the reliable, economical and resource-saving production of several identical, precision components from thermoset molding compounds in multi-cavity molding. The second step is the development of an injection molding machine capable of increasing the volume of processable polymer per cycle. This will result in more economical and energy-efficient large-scale production. As a third step, a recycling strategy is being developed for the sprue and the runner system, based on granulation of the cured plastic and its direct recirculation into the injection molding process as a reinforcing material.
The transfer to industrial applications will start with a function-integrated overmold for transponders used in timekeeping at sports events. Secondly, a directly cooled electric motor with integral lightweight housing (“DEmiL”), which has received several innovation awards, will be further developed into an electric motor-gearbox unit. The increased integration of functions aims to further improve the power-to-weight ratio.
The project plan is based on the parallel development of the three process innovations and the two product innovations. Fundamental investigations are being conducted to gain insights into active cavity balancing, shot volume increase and the recirculation of recycled materials. In parallel, two applications are being developed in the areas of structural lightweight construction with phenolic resin molding compounds and electronic packaging with epoxy resins. In terms of their carbon footprint, both applications benefit greatly from the three process developments and their implementation in a plastic construction. Finally, the large-scale production capability of the developed technologies will be demonstrated by installing and operating two pilot production lines.
The project consortium is made up of industrial and research partners along the entire value chain for thermoset plastics. As a system supplier of machines for plastics processing, KraussMaffei Technologies GmbH will further develop process technology for thermoset injection molding. Baumgarten automotive technics GmbH is contributing its experience as a provider of complete solutions in the high-volume production of thermoset injection molded components. On the process side, the Fraunhofer Institute for Chemical Technology ICT is advancing the development of active cavity balancing and sprue recycling. It is also developing the Lite2Duro electric motor-gearbox unit on the product side. The company GHD-Präzisions-Formenbau GmbH & Co. KG will investigate the integration of the newly developed balancing technology in injection molds. Technotrans GmbH is pursuing the overriding project objective of developing an active cavity balancer for injection molding, as a component for injection molds for thermosetting molding compound. The Karlsruhe Institute of Technology (KIT) - Institute of Vehicle Systems FAST (KIT-FAST) is further developing existing manufacturing simulation approaches for thermoset injection molding compounds in order to sharpen the prediction accuracy. The goal of Race Result AG within the framework of Lite2Duro is to increase the function integration for a timekeeping transponder through direct overmolding. Simutence GmbH will contribute its expertise as a provider of customized and highly specialized simulation solutions in the field of fiber-reinforced composite components and will handle the industrialization of the developed simulation approaches. The consortium is supported by the associated partner Sumitomo Bakelite Co., Ltd. which contributes material expertise to the project.
The Lite2Duro project is funded by the German Federal Ministry for Economic Affairs and Energy (BMWi) for a period of three years as part of the Lightweight Construction Technology Transfer Program.
Fraunhofer Institute for Chemical Technology ICT