LANXESS is currently introducing its hollow profile mixing technology to the market. Using this new lightweight design technology, plastic mixtures can be used to functionalize metal hollow profiles on a traditional injection machine. The resulting plastic-metal composite parts are compared to the hollow profiles that were previously functionalized with other technologies. In terms of torsional stiffness and strength.
"Hollow profile mixing technology has now developed to a very good level. We have carried out various development projects with our customers, some of which have entered the prototype stage." said Dr. Matthias Theunissen, a lightweight design expert at LANXESS. Potential applications of this technology in the automotive industry include beams, connecting rods, stabilizers and seat components. In addition, this new lightweight technology can also be used to manufacture ski poles and trekking poles, as well as components required by the furniture and construction industries.
Simple injection molding technology, short cycle time
The hollow profile hybrid technology is a further development of the traditional plastic-metal composite technology (hybrid technology) using sheet metal. The advantage of this new technology is that processors can achieve short cycle production, which is a typical feature of injection molding technology for mass production. Therefore, the production process is efficient and economical. Since no auxiliary equipment or mold technology is required, the cost of investing in this technology is relatively low. In addition, since it is possible to use hollow profiles with reasonable prices and relatively large dimensional changes, it also helps to improve the cost-effectiveness of the entire process.
Theunissen explained: "With the help of innovative tolerance management, we can prevent this type of material from damaging the mold or prevent leakage in the injection mold." Usually, a high pressure of more than 400-500 bar is generated, which brings the risk of deformation or destruction to the profile. "In this regard, we optimized the process so that the profile can withstand the pressure generated in the cavity without providing support from the inside." Theunissen said.
Reduce the weight of car beams by 30%
For hollow profile mixing technology, LANXESS provides highly reinforced polyamide 6, such as easy-flowing Durethan BKV60H2.0EF DUS060, which contains 60% by weight of short glass fiber. With high strength and high rigidity, these compounds can further improve the performance of corresponding parts. In a simulation study, LANXESS studied how to use these compounds in the design of automobile beams to obtain benefits. "We can reduce the weight of parts by approximately 30% compared to all-steel structures through design, and at the same time provide better mechanical properties in some aspects." Theunissen said.
LANXESS estimated typical load conditions and component characteristics, such as the vibration characteristics and stiffness of the steering wheel in the direction of gravity. This component also highlights the huge potential of this technology to achieve low-cost functional integration. For example, connecting A-pillars, and installing steering columns, instrument panels, weather control devices and airbags, etc., can all be achieved by direct injection. .
High-quality predictive simulation
LANXESS has developed new calculation models based on simulation tools for the hollow profile hybrid technology. Over the years, these simulation tools have proven their success in the application of traditional hybrid technology. In this way, the production process and the quality of the connection between metal and plastic can be accurately predicted. "For example, we can use these tools to accurately predict the maximum stress that hollow profile hybrid components can withstand and the point at which they will fail. In the process of working with customers, we use this expertise." Theunissen explained.
Using a newly developed sample, LANXESS verified the simulation results. Extensive testing of real components under static and dynamic loads confirmed the simulation results.