Kingfa Sci. & Tech. Co. Ltd and its subsidiary Guangzhou Kingfa Carbon Fiber Materials Development Co. Ltd., both from Guangzhou in China, supply their innovative materials in China for the manufacturing of lightweight door module carriers for the Ford Focus.
Kingfa worked very closely with German system supplier Brose Fahrzeugteile to develop its new continuous fiber reinforced material, called KingPly ™, to fulfil the high requirements set by Brose development. Brose designed the lightweight door module carrier with considerable weight saving targets while not sacrificing any performance requirements. More so: Brose even managed to increase the functional integration. This succeeded in a weight saving of about 35% compared to a standard injection moulding door module carrier and reduced the car weight of the 4 door model Ford Focus by more than 1 kg compared to a PP-LGF 30 door module carrier. Compared to a standard metal door concept without plastic carrier, this composite design can reduce the car weight by more than 5kg.
With its new composite materials based on UD layers, Kingfa advances into new areas of lightweight design. The thin single layers made of UD tapes, called KingStrong ™, are used to manufacture custom made semi-finished products in the form of sheets under the brand name KingPly™ for the customer, which are finetuned exactly to the application and its requirements. In the case of the door module, a very thin but strong multi layer material is composed to give the part stiffness and strength. The door module has many requirements: Stiffness, strength, NVH, acoustics and also sealing, as the carrier is on the division line between dry and wet within the door structure. The chosen material is using PP matrix and continuous glass fiber as reinforcement. The sheets are cut by Kingfa to the exact dimensions needed in the injection moulding tool, so that no cutting and waste is happening at the customers production.
„Now, even more efficient parts can be designed and manufactured using UD layers, which enable highly custom-made and optimized materials. They can be used even better to implement the lightweight requirements of the future than commonly used similar materials based on woven fibers.“, explains Martin Klocke, Vice General Manager Automotive Business of Kingfa Sci.&Tech. (Europe) GmbH, the European subsidiary located in Wiesbaden.
“Our newly developed thermoplastic composite materials have proven Kingfas innovative capacity and we hope to even better support our customers in their lightweight projects. To
achieve this, we invested heavily in the design and construction of our own in-house technology and manufacturing. The whole production setup was optimised such that we are ready to tackle high volume mass production. This is proven by this successful mas production project by Brose for Ford.”, says Zhonghu Ye, Vice General Manager Sales and Marketing at Guangzhou Kingfa Carbon Fiber Materials Development.
The thermoplastic composite materials from Kingfa can be processed reliably in the already known one-shot injection moulding process. The part manufacturer has optimised this process for the mass production of the door module to such an extend that it is able to offer cost attractive lightweight parts in high volume. An important feature of the process is a short cycle time and the fact that forming of the composite and injection happen in the same tool. The composite material is accompanied by Kingfas pultruded PP LGF grade, a perfect match to complement the lightweight design of the carrier. This grade was optimised to match current and future high requirements regarding VOC and odour for interior applications.
Kingfa is confident that its composite materials and compounds can be a solution for many cost-effective lightweight applications in the automotive industry in the future.
Kingfa is one of the leading global plastics compounders with sales of 25.3 billion RMB in 2018 and 6700 employees worldwide with the headquarter in Guangzhou, Canton province, China. The company has production and R&D sites in all major regions. Kingfa is developing and manufacturing tailor-made plastic materials for its customers in the automotive and E&E industry. Kingfa was founded in 1993 and since then has seen a very dynamic growth that lead the company from China into the world. Kingfa is listed at the Shanghai stock exchange.
Cautionary note regarding forward-looking statements
This news release may contain forward-looking statements. These statements are based on current estimates and projections of the management of Kingfa and currently available information. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. Kingfa does not assume any obligation to update the forward-looking statements contained in this news release or to conform them to future events or developments.