Lamilux: New type of GRP material for sandwich facings

The industry is increasingly backing sophisticated composites for the lightweight construction of commercial vehicles. They must be stable, light and very durable in order to meets the requirements of weight reduction and longevity while focusing on energy-efficient and sustainable mobility. With the new fiber reinforced composite LAMILUXplan High Impact, LAMILUX – the market leader in the production of GRPs in Europe – has developed a new facing material which combines all the positive features of thermoplastic and thermosetting materials and of sheet metals. It is primarily intended to be used as a surface for sandwich elements for side wall and roof structures. LAMILUX will present this composite material, which has extremely good impact resistance and tensile strength, at the Composites Europe trade fair in Essen.

With the fiber reinforced composite LAMILUXplan High Impact, it has been possible to combine the most compelling product advantages of three major construction materials in commercial vehicle design. It has the impact resistance and surface appearance of polished metal facings (such as aluminum, for example) while at the same time possessing the low thermal conductivity and elastic deformability of thermoplastic materials and having the high resistance to UV, weathering and corrosion and the rigidity, stability and low specific mass per unit area of thermosetting polymers. LAMILUXplan High Impact at the same time compensates for the disadvantages of the materials, such as the susceptibility of metals to corrosion and the poor paintability of thermoplastics.

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As Stefan Bachstein, Technical Director for LAMILUXplan, explains, "Due to its extreme impact resistance and tensile strength, our new material withstands the effects of even the strongest frontal forces." According to Bachstein, this has been proved in numerous standardized test series. Examples include the Charpy impact test according to ISO 179/2n, as well as the tests for flexural strength according to DIN EN ISO 14125/WKII and tensile strength according to DIN EN ISO 527-4/2/2. According to these tests, LAMILUXplan High Impact achieves an impact resistance of up to 100 kJ/m² and a flexural strength of 305 N/mm². The value for the tensile strength has been determined as being 240 N/mm². By way of illustration, a 1.0 centimeter wide strip of LAMILUXplan High Impact with a thickness of 0.8 millimeters only tears with a tensile loading upwards of 155 kilograms.

Stable, durable material with a high quality visual appearance
In order to achieve the material´s impact resistance, LAMILUX utilizes a new resin system. It provides LAMILUXplan High Impact with the necessary flexibility to absorb strong forces. The resin absorbs the stresses which are produced and transfers them into the reinforcing fibers. Depending on the scope of application and the customer´s requirements in terms of stability, these fibers can in turn be incorporated into the material in two or three plies, in various grammages and with different fiber orientations.

"We have developed this durable material with a high-quality, brilliant outer surface specifically for use as a facing for sandwich panels in vehicle construction," explains Technical Director Stefan Bachstein further. He goes on to say that the processing industry will profit in particular from the advantages which LAMILUXplan High Impact will bring as a thermosetting polymer material. "We can produce the material in all RAL and NCS shades and in colors customized according to client requirements. This means that a subsequent lacquer finish is not necessary, although it would be possible without any problems and without any complex surface treatment." According to Bachstein, the material further offers a high level of convenience in processing, as it is easy to bond and can be manufactured in widths of up to 3.20 meters.

More Information: www.lamilux.de

Composites Europe 2010, 14.-16.9.2010, Essen, Hall 10-11, St. E43

Lamilux Heinrich Strunz GmbH, Rehau

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