article details

Help Center

Light trunk recess for luxury cars

Industry News > Light trunk recess for luxury cars

Tepexdynalite continuous fiber reinforced thermoplastic composites are increasingly being used to replace metals in lightweight designs. One of lanxess's new applications for these composites is to make a slot in the trunk of the Mercedes-Benz S-Class to hold the 48-V on-board power battery. These composite parts can withstand high mechanical stresses and are about 30% lighter than similar metal plate parts. "In the event of a collision, ensure that the battery does not penetrate or damage the groove wall in any way. Our fabric-based composites are capable of achieving this goal with their high strength and stiffness." "Said Klaus Vonberg, PhD, lanxess Tepex application specialist. "The composite design also ensures that the trunk recess is airtight, preventing fluids such as water and battery electrolyte from seeping in or leaking out."

Cost effective functional integration

The safety parts are manufactured using an economical composite molding process using billets produced with water cutting machines and measuring approximately 110x80 cm. The billet is made from polyamide 6 based Tepexdynalite 102-RG600(2) and reinforced with two layers of continuous glass fabric. Lanxess's mobile polyamide 6 Duriton BKV60H2.0EF DUS060 is used as a reinjection material to enable the integration of fasteners and stiffeners at low cost. 60% of its mass is short glass fiber, which also makes it very strong and perfect for use with Tepex.

Complex molding process

Billet forming (draping) is carried out by a die press, which is a highly complex process due to the high tensile ratio, etc. This is because the composite material does not extend plastic like the metal sheet, but needs to be deformed in response to the movement of the fiber material (overhang), which means that the composite sheet must be continuously replenished from the outside in the forming process. If moved too far, the fibers can inhibit the molding process, leading to fracture and affecting subsequent processes.

Integrated simulation saves development cost

Lanxess uses a series of computational models to accurately simulate the overhang process to predict and analyze the molding effect and take appropriate measures. Lanxess can not only determine the optimal two-dimensional cutting geometry of the blank, but also perform virtual analysis of the forming behavior of the blank based on the customer's processing concept, thus identifying and eliminating defects as early as possible. There is a huge potential for savings when these processes are designed. "For the trunk grooves, we also determine when the critical shear Angle of the fabric is reached during the molding process, where the fabric will wrinkle and when the fiber will start to break," Vonberg said. "Our calculations and simulations also help ensure that the rounded corners of the component can withstand the intended load." In addition, the local orientation and distinct three-dimensional profile of the continuous fiber itself in the component area, such as rounded corners, are simulated. This is the prerequisite of using integrated simulation to accurately predict the performance of mechanical components. "All of this is part of the service we offer under the HiAnt brand, through which we support our customers' development experts in designing trunk grooves," Vonberg said.

More applications

In the mercedes-benz c-class, Tepexdynalite is now also used to make the trunk recess that houses the on-board power battery. "We also see great potential in the ELECTRIC vehicle space -- including safety equipment, complete battery system enclosures or components for the loading space provided under the hood, because our lightweight structural materials are much lighter than metal and help increase the range of electric vehicles." "Vonberg said, looking ahead.

previous：Plastindia 2022, the country's largest plastic show, has announced a postponement next：How to quickly separate black plastic packaging according to type

Light trunk recess for luxury cars

Return & Exchange

Fast Delivery

Member Discount