Combining composites and polyamide reduce auto component weight

Hybrid technology based on Tepex continuous fibre-reinforced composites overmoulded with Durethan polyamides has tremendous potential in lightweight automotive design as an alternative to metal parts, for example in the fabrication of front ends, brake pedals and seat shells, according to specialty chemicals maker Lanxess AG. The German firm already has a broad range of materials for this type of lightweight design. Together with its subsidiary Bond-Laminates, the manufacturer of Tepex, Lanxess regularly enhances this product range by adding new, tailored material variations, thereby incorporating the experience it has gained in numerous development projects. 

 

One current example is a new polyamide 6 compound with 55% short glass fiber reinforcement that will be marketed in the future under the name Durethan BKV 55 TPX. The advantage of this material optimised for processing with Tepex is its very good flowability combined with high strength and stiffness. It offers processors a wide processing window. “We see great application opportunities particularly for thin-walled lightweight composite parts with large flow length/wall-thickness ratios,” explained Dr Martin Wanders, Head of Global Applications Development in the High Performance Materials business unit (HPM) of Lanxess. 

 

The high flowability ensures that even very thin, geometrically challenging ribbed structures in areas of the mold far from the gate enter into a permanent material bond with Tepex – which in turn contributes to a reliable manufacturing process. “Furthermore, processors can move production to smaller injection molding machines with lower locking forces to gain greater flexibility in machine selection and production planning,” said Martin Klocke, Business Development Manager for Lightweight Construction in HPM.