TEPEX dynalite continuous fiber reinforced thermoplastic composite panels from LANXESS can be used to make large, highly integrated structural components for automotive lightweight designs. For example, the front bracket of the Mercedes-Benz GLE SUV is composed of two welded composite half shells. These two half shells are made of polypropylene TEPEX dynalite 104-RG600 (3) / 47% cross section and have a length of about 1.2 meters. It is about 0.35 meters wide.
Both shells are manufactured using a hybrid molding process using an injection mold with two cavities. This involves custom compound pre-cut molding, and gives additional functionality through injection molding. "This highly integrated, one-time manufacturing process is very cost-effective and can shorten the cycle time. The front-end support made of the shell is about 30% lighter than similar designs made of steel sheet, and has excellent crash performance and torsional stiffness." LANXESS Explains Henrik Plaggenborg, head of TEPEX Automotive, the high-performance materials (HPM) business unit.
Front-end support is a product developed jointly by Mercedes-Benz Technology Center, LANXESS and other industry partners. Its hollow cross-section, along with the strength and stiffness of the composite material, is the reason behind the component's excellent crash performance and is vital to safety. Its good mechanical elasticity is also proven by the fact that the components do not need to be reinforced with metal sheets in the area around the hood latch, as is usually the case with purely injection-molded front-end supports.
The front bracket has many openings and pipes to provide fresh air to the engine. These are produced by the injection molding stage of the hybrid molding process combined with the welding of the subsequent two half-shells. The ribs, brackets, guide channels and attachments and the openings of the screw bosses are also integrated directly. "The functional integration minimizes the number of components required for manufacturing front-end support. This reduces logistics and makes subsequent assembly faster and easier. This also helps to create A cost-effective solution. "
Thanks to the joint development of the hybrid molding process, the visible part has excellent visual quality. According to Sontag, "enhanced fiberglass rovings are arranged very evenly on the surface, giving them a sporty feel reminiscent of carbon fiber." There is no need to upgrade components with expensive paint or anticorrosive coatings.
LANXESS and its automotive partners see front-end support as a breakthrough development in lightweight design of electric vehicle structures. Plaggenborg explained: "First, finding metal alternatives has reduced weight, which has increased vehicle range per battery charge. In addition, the cost-effective hybrid molding process, feature integration, and ability to skip spraying have helped to significantly reduce The cost of electric vehicles enables them to compete with gasoline-powered vehicles. In addition to the support of front ends, doors, and bumpers, possible applications of TEPEX dynalite in electric vehicles include the carrier of electrical and electronic modules, load compartments, battery housings, and Lids, structural components of the "greenhouse" part of the vehicle, and structural trim of the lower body area to protect the battery.
HPM provides comprehensive support to its partners in the development of front-end support in the form of HiAnt customer service. Taking stereo cutting simulation as an example, the Tepex pre-cut parts are optimized and processed. Sontag said: "The pre-cut is slightly pre-made during the transfer to the injection mold, which makes subsequent coverage easier and helps ensure high surface quality." Experts from HPM also assisted with process development, sample collection And the start of serial production. HiAnt's services range from designing components and selecting materials to designs that are optimized for expected loads, support tool design, and help ensure successful production.