Tepex continuous fiber reinforced thermoplastic composites have great potential in many areas, including the lightweight construction of structural safety components. A child seat head restraint developed as a technology demonstrator can be used to illustrate the opportunities offered here.
Thermoplastic composites reinforced with continuous fibers
Child seat headrest
The component is produced by a particle foam composite injection molding (PCIM) process.
Experts in lightweight construction explained: "Compared to commercially produced component variants, the manufactured inserts can reduce the weight of the headrest by up to 30% and have fairly good crash performance. This also simplifies the production process.
Efficient production process
For head restraints, project partners have developed alternative production processes based on PCIM. To strengthen the headrest in a single position and reduce weight, they used a custom insert made of Tepex dynalite 104-FG290 (4) / 47%. This is a polypropylene-based composite that can be reinforced with two continuous layers of glass fiber roving. The inserts are formed in a single process using an injection molding tool with a steering plate, and short glass fiber reinforced polypropylene compounds are injected backwards to integrate the support structure for the headrest and backrest. A second tool was then used to back foam the pre-made inserts using expanded polypropylene (EPP) -based particulate foam.
From six to one
In contrast, current reference headrests are mass-produced using multiple individual components. The support structure consists of long glass fiber reinforced polypropylene. It uses four polypropylene feet to assemble with separately foamed EPP components.
The project leader explained: "Not only is the highly integrated new production process more energy efficient than previous processes, but it also produces finished parts directly. As a result, the total number of parts has been reduced from six to one, from logistics and The cost of machinery required also reduces production costs. "
The current version of the headrest assembly with fiberglass can reduce weight by about 26%, although there is still more potential. According to Schramm, "If carbon fiber-based reinforcements are used in composite semi-finished products and injection molding materials, the weight after assembly will be reduced by nearly 30%."
Potential application potential, including applications in other components
We see great potential for new processes in the production of baby carriers, backrests and armrests, as well as new, highly sophisticated seat concepts for seat shells or shuttle comfort seats in autonomous vehicles, VIP and family buses. Especially electric cars will benefit from light seats.