LANXESS`s Tepex continuous fiber-reinforced thermoplastic composite material is an ideal choice for the production of structural parts for driver assistance systems. An example is the battery bracket that powers the Intelligent Drive, the highly automated driving assistance system of the S-class car, in response to a sudden power failure.
The bow-shaped bracket is manufactured by Poeppelmann Kunststoff-Technik GmbH & Co. KG, headquartered in Löne, Germany. The raw material used is Tepexdynalite 104-RGUD600(4)/47% based on polypropylene. The manufacturing method is a two-step method that combines the molding (overhang) of the composite material with injection molding. "Composite design means that the finished product is 40% lighter than the corresponding metal product." The relevant person said. "The injection molding step can also integrate functions, which not only makes it easier to install the bracket, but also reduces the logistics workload. All of these help reduce manufacturing costs."
Composite material design means the finished product is 40% lighter than the corresponding metal product
Optimized force distribution
The role of the bracket is to firmly support the battery weighing about 10 kg in the trunk of the car only by clamping, and it can keep the battery in a fixed position even when the car is subjected to a huge acceleration force after a collision. The bracket is designed to ensure that most of the force is transmitted from the point of application through the continuous glass fiber of the composite material. This can take full advantage of the high strength and rigidity provided by Tepex blanks. "The advantage of our composite materials is that, unlike fiber-reinforced injection molding compounds, these materials will not creep under continuous high stress, so they will not deform. This ensures that the battery is always kept in a fixed position." The relevant person said. The blank also has a high fatigue strength, which can ensure that the material will not become brittle and cracked due to frequent or severe vibrations (such as pits) over time.
Clamping control device
The functional equipment integrated into the bracket during the injection molding process includes the cable guide and the bases and fasteners of the two control devices. The relevant person said: "These two devices can be easily clamped to a fixed position during the installation process, so there is no need to spend time screwing them in."
Material tightly integrated
The polypropylene matrix of Tepex material is reinforced with four layers of continuous glass fibers, which are arranged in roughly the same direction. Injection molding compounds reinforced with short glass fibers are also based on polypropylene. Since the bonding base material and the injection molding material match, the two can be tightly combined. Coupled with the high specific stiffness of the composite material, the strength and stiffness can be further increased. "The relevant personnel said.
Anti-corrosion and electrical insulation
Another advantage of this composite semi-finished product is its ability to prevent corrosion, so it is easier to transport and store than metal coils. The electrical properties of this structural material also play an important role. "Because the main body and metal parts of the battery can be electrically insulated, the risk of short circuits can be significantly reduced. In contrast, parts made of metal need to take additional measures to prevent short circuits." Related personnel said.