The front support of the Mercedes-Benz GLE SUV includes two welded composite half shells, made of polypropylene-based TEPex dynalite 104-RG600 (3) / 47% cross-section, about 1.2 meters long and 0.35 meters wide. Both housings are manufactured using a hybrid molding process, using injection molding tools with two cavities. This involves forming custom composite pre-cuts while providing additional features through injection molding.
HeNRik Plaggenborg, head of Tepex Automotive at Lanxess' High Performance Materials (HPM) business unit, explained:
"This highly integrated, one-time manufacturing process is very cost-effective and reduces cycle time. The front-end bracket made of shells weighs about 30% less than the design weight made of steel and has excellent crash performance and torsional stiffness. "
No need to reinforce around the hood latch
The front bracket is a product developed by the Mercedes-Benz Technology Center, LANXESS and other industrial partners. Its hollow profile cross-section, together with the strength and stiffness of the composite, is why the parts that are critical to safety have excellent crash performance. Its mechanical elasticity is also demonstrated by the fact that the part does not need to be reinforced with a metal plate in the area around the hood latch, which is usually the case for a purely injection-molded front-end support.
High-level functional integration
The front bracket has multiple openings and ducts to provide fresh air to the engine. These are produced through the injection phase of a hybrid molding process combined with subsequent welding of the two half-shells. Reinforcements, brackets, guide channels and openings for connectors and screw bosses are also integrated directly.
Tilmann Sontag, Project Manager at HPM Tepex Automotive Group, said:
"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 create a cost-effective solution"
Carbon appearance surface
Thanks to the common development of the hybrid molding process, visible parts have excellent visual quality.
According to Sontag, "Reinforced fiberglass rovings are arranged very evenly on the surface, reminiscent of carbon fiber." No need to use expensive paint or anticorrosive coatings to "upgrade" components.
Pave the way for light electric vehicle design
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 can reduce weight, thereby increasing the range of vehicles that can be charged per battery. In addition to this, the cost-effective hybrid molding process, feature integration, and ability to skip painting can help significantly reduce the cost of electric vehicles. Cost, enabling them to compete with combustion-powered competitors. "
In addition to front end, door, and bumper support, Tepex dynalite may be particularly useful in electric vehicles. Applications include carriers for electrical and electronic modules, loading chamber wells, battery housings and covers, structural components of the "greenhouse" portion of the vehicle, and bottom areas The structure is decorated to protect the battery.
HiAnt-Creating added value for customers
HPM provides comprehensive support to its partners, developing front-end support in the form of HiAnt customer service. For example, use overhang simulations to optimize tool design and processing of heating and soft Tepex pre-cuts.