INNOVATION | ENGINEERING THERMOPLASTICS
The portfolio has been growing ever since. In 2018, Ineos Styrolution introduced a “carbon look” version, StyLight Aesthetic S C200-1, with higher fibre density and improved stiffness, followed by a PP- based version. A representative says the material is particularly popular in the automotive, electronics and the toys/ sports/leisure industries. The success of the material led to plans, announced last April, to build a dedicated production site.
Location has not yet been decided, but wherever it is, it should be operational in 2022.
One of the latest examples of how
Above: A demonstrator for a rear seat backrest is being devel- oped in the FOREL FuPro mylti-partner project in Germany
Lanxess’s Tepex continuous-fibre-reinforced thermoplastic composite materials can be used in injection moulding to produce lightweight structural compo- nents is an A-pillar developed by Porsche’s 3D hybrid design, intended to improve crash safety in convertibles and roadsters. It has been em- ployed for the first time in the Porsche 911 Cabriolet. The pillar contains an insert
Right: Rome snowboard binding
made from high-strength steel. This is supported from the inside by a formed blank of the polyamide-6-based Tepex Dynalite 102-RG600(6)/47% and by a ribbed structure made from Durethan AKV30H2.0 short glass fibre reinforced PA66. This
structure is bonded by friction with a structural foam. “The strength and rigidity of the hybrid insert ensures that the A-pillar is just as good at with- standing rollovers as previous designs featuring high-strength steel tubes,” says Lanxess. “However, it is around 5kg lighter.” Through its HiAnt customer service operation,
Lanxess provided Porsche and part producer L&L Products with extensive support in the develop- ment of the hybrid inserts and the A-pillar. “Ser- vices included simulating the forming (draping) of the Tepex blanks, simulating filling for back-injec- tion and calculating warpage. We also determined material characteristics to simulate the mechanical behaviour of the A-pillar and made these figures available to Porsche,” says Jean-Marie Olivé, expert in application development at Lanxess. PolyOne bolstered its composites business almost four years ago when it acquired Polystrand, which makes tapes and multi-ply laminates suitable for over-moulding. One example is equipment for winter sports from Rome Snow- boards.
In creating its Black Label, Rome sought to add what is known as a premium “high- back” to its binding collection that would be flexible and durable, providing highly responsive performance in an ultra-light, high-tech binding. The design team at Rome worked closely with the
PolyOne Advanced Composites technical team and a local thermoformer, trialling various
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