Automotive Design
The multi-layer tubes are lightweight replacements for rubber hoses and reinforced lines. The MLT 8000 multi-layer tubing system has since proven its performance in vehicles worldwide. The current car uses MLT 8000.3 with an orange outer layer. This system is around 870g lighter than cooling line systems with steelflex tubes, a weight reduction of more than 70 per cent. The coolant lines have three layers: the inner layer is
a specially adapted grade of polypropylene; the second is an adhesion promoter layer; and the outer layer consists of the Vestamid (or bio-based Vestamid Terra). Evonik’s bio-based polyamides have been used
commercially since 2010 as mono-layer tubes in air brake lines of utility vehicles, and other applications, but this is the first time they have been used in multi- layer tubing systems for coolant lines.
Composite gain
BASF has moved into a new area, with a new method for making fibre-reinforced thermoplastic automotive parts. The Ultracom concept has already been used to create a seat pan for the Opel Astra OPC. Ultracom combines three components: a continuous fibre woven nylon fabric; a range of glass-filled nylon
and PBT moulding compounds; and engineering support, including elements such as computer simulation. The fabric is placed into a special injection mould
and heated until it softens. The moulding compound can then be used to ‘overmould’ the fabric, which creates structures such as ribs to add strength. BASF is initially aiming to create two types of component: those with high stiffness, or those with high energy absorption. This will be done by changing the overmoulding compound in each case. The company has built a pilot line to create the
parts, and says the cycle time of around 60 seconds could be reduced to 50 seconds with the use of improved automation. More ‘overmoulding’ material grades will also
be developed in the near future, says BASF. Before that, examples of moulded parts will be seen at the forthcoming K2013 show in Germany, which takes place in October.
On the bounce
Car maker Fiat has redesigned the jounce bumper system on its latest Punto. Made from a modified version of DuPont’s Hytrel thermoplastic elastomer
Fig. 3. BASF’s Ultracom concept combines continuous fibre nylon fabric, overmoulding compounds and engineering support to create composite parts.
www.engineerlive.com 9
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60