NetComposites
Attwater

New Application for Tepex from LANXESS in Large Series Production

04 April 2017

Increasing numbers of automotive manufacturers are using Tepex continuous-fibre-reinforced thermoplastic composite semi-finished products from LANXESS for the lightweight design of parts in large series production.

According to LANXESS, an emerging application for the composite is the door module carrier for a compact-class vehicle from an international automotive manufacturer. LANXESS explains that it recently received a contract from German system supplier Brose Fahrzeugteile to supply the carrier’s manufacturer, ElringKlinger, with the composite material.

“The structural component exemplifies the tremendous potential opened up by our composite in cost-effective lightweight design. With our know-how in materials, virtual component design and simulation of the manufacturing process, we’ve made a key contribution to this successful development,” says Henrik Plaggenborg, Head of the Technical Marketing & Business Development Tepex Automotive group. LANXESS subsidiary Bond-Laminates, which develops and manufactures Tepex, will be supplying ElringKlinger in Europe with the Tepex composite sheet.  

The component is the result of a close partnership between Brose, ElringKlinger and LANXESS over a number of years. The weight is said to have been cut by around 1.6 kilograms per vehicle compared with injection-moulded component designs. “With four door modules, weight savings of approximately five kilograms per vehicle are possible compared with a steel version,” says Plaggenborg.

The door module carrier is produced in a hybrid moulding process using forming and back-injection of Tepex directly in the injection mould. “The one-shot process industrialised by ElringKlinger eliminates the forming tool, while also enabling cost-cutting integration of functions. These two things are the key to making the component cost-effective,” says Harri Dittmar, Project Manager in the Technical Marketing and Business Development Group.  

Tepex has already established itself in various series applications in structural lightweight automotive design. For example, it is used to produce front-end carriers, bumper beams, infotainment brackets, underfloor protection paneling, brake pedals, battery consoles, seat shells and seat backrests. “By annually supplying blanks in quantities of seven-digit figures for door module carriers, we’re once again demonstrating Tepex’s suitability for large series production on the market,” says Dr. Christian Obermann, Managing Director at Bond-Laminates.

 






Related / You might like...

Dilutec Celebrates 23 Years

Brazilian gelcoat and thinner manufacturer Dilutec celebrates 23 years in business this month.

TFP Presents Nonwoven Solutions for Transportation

Technical Fibre Products (TFP) will exhibit nonwovens for use in surface finishing, imparting EMI shielding or fire protection, and other transport applications, at the JEC Conference on The Future of Composites in Transportation, taking place in Chicago, US, on 27-28 June.

Visitor Registration Opens for Advanced Engineering 2018

Advanced Engineering 2018, the UK’s annual gathering of OEMs and engineering supply chain professionals, has opened registration for its 10th anniversary show. The first 50 people signing up will be offered a free Ultra High Capacity Power Bank for mobile phones and laptops, to be picked up at the show.