TECHNOLOGY | REINFORCEMENTS
Above: PolyOne has added a
thermoplastic composite innovation laboratory at its Polystrand manufacturing facility in the US
continuous fibre-reinforced thermoplastic, where Lanxess is a key player with its Tepex product line. A recent example can be seen in a lightweight structural A-pillar developed by Porsche’s 3D hybrid design and intended for use in cars such as convertibles and roadsters. The first application of the technology can be seen in the Porsche 911 Cabriolet. Its A-pillar features an insert made from high-strength steel which is supported internally by a formed blank of PA6-based Tepex dynalite 102-RG600(6)/47% thermoplastic sheet and a ribbed injection moulded structure made from short glass fibre reinforced PA66 Durethan AKV30H2.0. This is bonded together using friction welding of a special structural foam—L-5235—developed by L&L Products.
In terms of strength and rigidity, the hybrid
insert A-pillar design matches the rollover performance of previous designs using high- strength steel tubes but is around five kilograms lighter. As this weight reduction is achieved in the upper section of the vehicle, it also lowers the car’s centre of gravity so improves vehicle dynamics. “The excellent mechanical performance of the
hybrid A-pillar demonstrates that hybrid inserts based on steel sheet, Tepex blanks, polyamide 6 or polyamide 66 variations of Durethan as a back- injection material and on a structural foam such as L-5235 also offer considerable potential for use in structural lightweight vehicle body design. That applies to electric vehicles in particular, as their heavy batteries give them a high impact mass,” says Henrik Plaggenborg, Head of Tepex Automotive at the Lanxess High Performance Materials (HPM) business unit. Other potential applications for the hybrid composite elements include reinforcing cross- members and side members, B- and C-pillars, load-bearing battery parts or door components that are critical to safety. Tepex dynalite is already used in series
production at Porsche for another safety-critical hybrid moulded component—the brake pedal for the Porsche 918 Spyder, Porsche Macan and Porsche Panamera NF. The part is claimed to be the first all-plastic brake pedal to be used in series automotive production. Hybrid applications are also being targeted by
PolyOne, which developed a continuous fibre reinforced thermoplastic overmoulded hybrid solution for a new snowboard binding. The recently-launched Rome Black Label snowboard binding is made using Polystrand continuous fibre reinforced thermoplastic composite laminate combined with a reinforced polyamide compound via injection moulding. The ultra-lightweight binding is said to offer users very good torsional flex without compromising on strength and power. PolyOne has recently added a thermoplastic composite innovation laboratory within its Polystrand manufacturing facility at Englewood in Colorado, US. The company says it includes the latest injection and compression moulding equipment for overmoulded composite part sampling and prototyping, as well as advanced
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PHOTO: POLYONE
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