Thermoplastic composite materials help achieve lightweight, energy saving and emission reduction

Tepex is a family of continuous fiber-reinforced thermoplastic composites from specialty chemicals company LANXESS for lightweight applications designed for passenger car structural componen.

Typically, these applications need to meet a very stringent set of requirements in a cra.

These A-pillars contain inserts made of high-strength steel with internal supports made of polyamide-6 based TEPEX Dynalite 102-RG600(2)/47% formed blanks and Durethan AKV30H

The entire hybrid insert is friction-bonded with L-5235 structural foam developed by L&L Products, whose strength and stiffness ensure the A-pillar has the same rollover resistance as the original high-strength steel tube design, while reducing weight by approximately five kilogra.

Structural lightweight body design holds unlimited potential

“The excellent mechanical properties of this hybrid A-pillar are evidenced by the post-injection molding of steel sheet, Tepex billet, Durethan polyamide 6 or polyamide 66 compound, and hybrid inserts based on structural foams such as L-5235 can be used for post-injection moldi.

Other potential applications for this hybrid composite element include reinforcement of cross-member rails, B-pillars and C-pillars, load-bearing battery components or door components that are critical to vehicle safe.

One-step post-injection molding process

These hybrid composite elements are developed and manufactured at L&L Products' plant in Strasbourg, Alsace, Fran.

The first step in the manufacture of reinforcing elements is the one-step forming of the Tepex blank by means of hybrid forming techniqu.

After the cladding is complete, the part is mounted directly to the body, both of which are simultaneously processed by a cathodic dip coating (KTL) proce.

Facilitate part design

As part of its HiAnt customer service, LANXESS fully supported Porsche and L&L Products in the development of the hybrid insert and A-pill.

First all-plastic brake pedal

In addition, Tepex dynalite has been used in series production of another critical safety component for Porsche - the brake ped.

As the first mass-produced all-plastic brake pedal, the component won first prize in the Automotive Innovation Awards 2016 in the Body Interior category, organised by the Central European Division of the Society of Plastics Engineers (SP.