Tepex dynalite continuous fiber reinforced thermoplastic composites are increasingly used as a substitute for metals in lightweight designs. A new application of these composite materials from LANXESS is the manufacture of load compartments installed on S-class cars to accommodate 48V on-board power batteries. Composite parts can withstand high mechanical stress and are about 30% lighter than similar sheet metal parts. Related personnel said: "In the event of a collision, the battery must not penetrate or damage the groove wall in any way. The high strength and rigidity of our fabric-based composite material ensures this. The composite material design also ensures the tightness of the load compartment and prevents The in and out of liquids such as water and battery electrolyte."
Function integration to reduce costs
The safety parts are manufactured economically using a hybrid molding process, using a blank (produced by a water jet cutter) about 110 x 80 cm in size. The blank is made of TEPX DYNALITE 102-RG600 (2) based on polyamide 6 and reinforced with two layers of continuous glass fiber fabric. Durethan BKV60H2.0EF DUS060 easy-flowing polyamide 6 produced by LANXESS is used as a post-injection material for cost-saving fasteners and ribs. 60% of its mass is composed of short glass fibers, which also makes it very strong and rigid, perfectly matching Tepex.
Complex molding process
The forming of the blank is carried out by compression moulding, which is a highly complex process, especially due to the high draw ratio. This is because the composite material does not expand plastically like a metal plate, but deforms with the movement of the fiber material, which means that the composite material must be continuously supplied from the outside during the molding process. If the movement is too large, the fibers will inhibit the forming process, causing breakage and affecting the rest of the process.
Integrated simulation saves development costs
LANXESS uses a series of calculation models to enable it to accurately simulate the molding process to predict and analyze the molding effect and respond accordingly. LANXESS can not only determine the best 2D cutting geometry of the blank, but also perform a virtual analysis of the forming behavior of the blank according to the customer's mold concept, so as to identify and eliminate defects as early as possible. This creates huge savings potential in the design of these processes.
A related person said: “For the load compartment, we also determined when the critical shear angle of the fabric was reached during the molding process, the position where wrinkles were formed, and the time when the fiber began to break. Our calculations and simulations also help to ensure that the components are The rounded corners can withstand the expected load. We also simulated the local orientation of the continuous fiber itself in the area of the component with obvious 3D contours (for example in the rounded corners). This is a prerequisite for accurately predicting the behavior of mechanical components based on integrated simulation. All this They are all part of the services we provide under the HiAnt brand, through which we support our customers’ development experts to design the load compartment well."
Further series of applications
In the C-class sedan, Tepex dynalite is now also used to make load compartments for accommodating on-board power batteries. A related person said: "Looking forward, we also see the huge potential of electric vehicles-so in terms of safety devices, complete battery system housings or load space components available under the engine-because our lightweight structural materials are lighter than metals. Much, so it helps to expand the scope of use in electric vehicles."