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Lanxess introduces hollow profile blending technology

Industry News > Lanxess introduces hollow profile blending technology

· The first projects with customers have entered the prototype stage

· Innovative tolerance management for profiles of different sizes

· Hollow profiles do not require internal support during production

· Accurately simulate the manufacturing process and component performance


Lanxess is currently bringing its hollow profile blending technology to market.

With this new lightweight design technology, hollow metal profiles and plastic mixtures can be functionalized on traditional injection molding machines.

This enables the torsional stiffness and strength of plastic-metal composite components to be much higher than previously achieved using other hollow profile functionalization technologies.

"Hollow profile mixing technology has now advanced to a very advanced level and we have carried out various development projects with our customers, some of which are in the prototype stage," said Matthias Theunissen, Lanxess Lightweight design specialist.

Potential applications for the technology in the automotive industry include dashboard beams, connecting rods, stabilizers and seat parts.

The new lightweight technology could also be used to produce ski poles and hiking poles, furniture and components for the construction industry.


The injection process is simple and the cycle is short


Hollow profile mixing technology is a further development of the "traditional" plastic-metal composite technology (mixing technology) using sheet metal.

The overall advantage of this new technology is that processors can achieve shorter manufacturing cycles, which are typical of injection molding in mass production.

Therefore, the manufacturing process is efficient and economical.

Investment costs are also kept low by eliminating the need for assistive devices or die technology.

The cost effectiveness of the process is also enhanced by the availability of affordable hollow profiles with relatively large size differences.

As Theunissen notes: "Thanks to innovative tolerance management, we can prevent this type of profile from damaging the mold or preventing leakage of the injection mold cavity."

When thin wall hollow profiles are coated with molten plastic, high pressures of 400-500 bar are usually generated in the cavity.

Therefore, profile deformation or damage risk is very high.

"We have optimized the process so that the profile can withstand the pressures that occur without having to support it from the inside."

His said.

 

Reduce the weight of dashboard beams by 30%


For the hollow profile blending technology, Lanxess offers highly reinforced polyamide 6 products such as the highly mobile Duryton BKV60H2.0EF DUS060 with 60% short glass fiber by weight.

With their high strength and stiffness, these blends further enhance the performance of the corresponding components.

In a simulation study, Lanxess looked at the benefits of using these blends in the design of vehicle dashboard beams.

"The components can be designed to weigh about 30 percent less than an all-steel structure, while providing better mechanical properties in some respects."

His said.

Lanxess calculated typical load conditions and component performance, such as vibration characteristics and steering wheel stiffness in the direction of gravity.

"This component also highlights the great potential of this technology for low-cost functional integration.

For example, a-pillar connectors and mounting parts for steering columns, instrument panels, climate controls and airbags are all directly molded.


Simulation studies of high predictive quality


Lanxess has developed new computational models for hollow profile mixing based on simulation tools that have proven successful in "traditional" mixing applications over the years.

These tools can accurately predict the production process and the quality of the connection between metal and plastic.

"For example, these tools help us accurately predict the maximum stress that the hollow profile mixture will undergo and the point in time when it will fail.

We bring that expertise to work with our clients."

"Theunissen said.

Lanxess validated the simulation with newly developed samples.

Extensive testing of real components under both static and dynamic loads confirmed the simulation results.



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