MATERIALS | THERMOPLASTIC COMPOSITES
Right: The new Sienna generation features
first-of-its-kind third row free-standing seatbacks
and in a way that is suitable for large-scale production.” The fully consolidated semi-finished products
with Tepex Dynalite have a thermoplastic matrix that is typically reinforced with layers of continuous glass-fibre fabric. The brake pedal for the battery-electric sports car uses a composite structure with a PA 6 matrix, which contains UD fibre layers inside and fabric layers with fibres arranged at 45° angles on the two covering layers. The inner layers are what give the compo- nent its excellent tensile and bending strength. Tapes are thin plastic strips with UD oriented,
high-strength continuous fibre systems embedded in the thermoplastic matrix. Multiple tapes with glass-fibre rovings are used in the brake pedal to reinforce the bottom of the component. Since the tapes and the Tepex insert consist of mutually compatible plastic matrices, the tapes can simply be welded onto the Tepex insert using a laser. This results in tailor-made laminates with fibre layers that follow the load paths precisely and are adapted to the exact load-specific component requirements. The covering layers of the insert with their 45° fibre layers, combined with the tapes on
top, ensure the high torsional strength of the pedal. The brake pedals are manufactured in an automated process using hybrid moulding in short cycle times suitable for large-scale production. The method integrates draping of the Tepex insert and the tapes in the subsequent injection moulding process. The first stage of production involves aligning the tapes precisely using optical measuring systems and then positioning them on the Tepex insert so that they can be welded to it. This assembly is thermo- formed and then back-moulded with PA 66. BASF has collaborated on lightweighting
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IMAGE: BASF
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