FIBERIM TM 14/03/00 New Materials for Variable Fiber Injection David Gibala Andreas Rothacker New Plastics 2000 Conference Brussels, Belgium March 14, 2000

FIBERIM TM 14/03/00 Objectives l Describe Variable Fiber Injection (VFI) Process

FIBERIM TM 14/03/00 Objectives l Describe Variable Fiber Injection (VFI) Process l Discuss Benefits and Uses of VFI

FIBERIM TM 14/03/00 Objectives l Describe Variable Fiber Injection (VFI) Process l Discuss Benefits and Uses of VFI l Demonstrate Broad Range of Applications and Physical Properties

FIBERIM TM 14/03/00 l Process to Produce Polyurethane Composites l Uses Fiberglass Roving l Chopped to Variable Lengths l Glass “Injected” into Mixhead l Automated One-Step Delivery of Polyurethane and Fiberglass Cannon InterWet TM - Krauss-Maffei LFI-PUR TM What is Variable Fiber Injection?

FIBERIM TM 14/03/00 Typical VFI Process Schematic PU-Fiber Mix Mold Isocyanate Polyol Metering Pumps Mixhead Chopper Fiber Roving Robot

FIBERIM TM 14/03/00 Simplified Schematic of VFI Mixhead Polyol Isocyanate Glass Roving Clean-out Piston Chamber Chopper Pour Piston

FIBERIM TM 14/03/00 Benefits of Variable Fiber Injection Process l Control of Fiber Length l Uniform or Distribution of Fiber Lengths l Ability to Change of Length During Pour

FIBERIM TM 14/03/00 Benefits of Variable Fiber Injection Process l Control of Fiber Length l Uniform or Distribution of Fiber Lengths l Ability to Change of Length During Pour l Integration with Robotics l Accurate Placement of PU-Fiber Mix l Ability for Multiple Pour Patterns

FIBERIM TM 14/03/00 Benefits of Variable Fiber Injection Process l Control of Fiber Length l Uniform or Distribution of Fiber Lengths l Ability to Change of Length During Pour l Integration with Robotics l Accurate Placement of PU-Fiber Mix l Ability for Multiple Pour Patterns l Potential for Enhanced Economics l Lower Cost Fiberglass Roving l Reduced Labor and Handling l Waste Reduction

FIBERIM TM 14/03/00 Applications and Properties of FIBERIM TM Produced with VFI Process l Broad Range of Properties and Applications Are Possible: l Versatility of Polyurethane Chemistry l Unique Features of VFI Process

FIBERIM TM 14/03/00 l Broad Range of Properties and Applications Are Possible: l Versatility of Polyurethane Chemistry l Unique Features of VFI Process Ù SPG’s from Ù Glass Content to >50% by Weight Applications and Properties of FIBERIM TM Produced with VFI Process

FIBERIM TM 14/03/00 Applications and Properties of FIBERIM TM Produced with VFI Process l Current and Potential Applications Seat Pans Sun Shades Door Panels Package Trays Truck Box Panels

FIBERIM TM 14/03/00 Case 1: LD-SRIM Door Panel

FIBERIM TM 14/03/00 Table 1 - Physical Properties LD-SRIM Door Panel: FIBERIM TM vs. Traditional Technology

FIBERIM TM 14/03/00 Case 2: High Glass-High Density Composite

FIBERIM TM 14/03/00 Table 2 - Physical Properties High Density Composite: FIBERIM TM vs. Traditional Technology * 12.5mm/35mm - 2:1 Ratio

FIBERIM TM 14/03/00 Summary 4 Describe Variable Fiber Injection Process 4 Conventional PU Metering Equipment 4 Modified Mixhead 4 One-Step PU-Fiberglass Mixing

FIBERIM TM 14/03/00 Summary 4 Describe Variable Fiber Injection Process 4 Discuss Benefits and Uses of VFI 4 High Fiber Content and Control 4 Lower Cost Potential

FIBERIM TM 14/03/00 Summary 4 Describe Variable Fiber Injection Process 4 Discuss Benefits and Uses of VFI 4 Demonstrate Broad Range of Applications and Properties 4 Low to High Density 4 Wide Glass Content Range 4 Diverse Application Requirements

FIBERIM TM 14/03/00 Acknowledgements Co-Author: Andreas Rothacker Numerous Huntsman Polyurethanes Colleagues