Great potential for use of Tepex in innovative vehicle concepts

  • Reinforced structural insert for A-pillar with Tepex
  • Infant carrier with ultralight, composite-based headrest
  • Trend towards sustainable composites in the sports, automotive and IT industries

Cologne
LXS-IMG_BoothDesign_JEC2020_1A.jpg
Model of the booth of LANXESS subsidiary Bond-Laminates at the JEC. One focus will be on a wide range of applications of Tepex composites in the lightweight construction of electric vehicles, in seat designs for autonomous driving and in safety-critical components such as child seats and infant carriers. Photo: LANXESS AG
New trends in transportation are opening up a wide range of potential applications for semi-finished products made with the Tepex continuous-fiber-reinforced thermoplastic composite from LANXESS, which has long since become established in large-scale production. “The focus of our activities at JEC World will therefore be on a wide range of applications of our composites in the lightweight construction of electric vehicles, in seat designs for autonomous driving and in safety-critical components such as child seats and infant carriers,” explains Henrik Plaggenborg, head of the Tepex Automotive Group at LANXESS. Tepex is developed and produced by LANXESS subsidiary Bond-Laminates GmbH in Brilon, Germany. Additional thematic focal points at the Bond-Laminates JEC World stand will include new material and technological developments for consumer electronics and the IT industry as well as sustainable composites for the sporting goods industry and laptop manufacturers, for example. Tepex applications that require outstanding flame-retardant properties will also feature.

Weight savings around the roof of the vehicle



Lightweight design is gaining in importance due to increasingly strict exhaust regulations and the move towards electric vehicles. Tepex also opens up enormous potential for weight savings in the vehicle body. LANXESS will be demonstrating this at JEC World, using the example of an A-pillar with a 3D hybrid design that Porsche has developed for vehicles such as convertibles and roadsters and is used for the first time in the Porsche 911 Cabriolet. It comprises an insert made from high-strength steel, a supportive and formed section of Tepex, a ribbed structure made from a polyamide 66 Durethan, and a structural foam. “Thanks to the hybrid insert, the A-pillar is just as stable in the event of rollovers as previous designs featuring a high-strength steel tube but it is around five kilograms lighter,” says Plaggenborg.

Headrest up to 30 percent lighter



A child seat headrest developed as a technology demonstrator by LANXESS partners as part of a project funded by the German Federal Ministry for Economic Affairs and Energy will also be on show. It is produced in a particle-foam composite injection molding (PCIM) process and contains an insert made from Tepex. “In comparison with the commercially produced component variant, the weight of the headrest is up to 30 percent lower without compromising its excellent crash performance. The production process is also simplified because the number of parts is reduced from six to one,” explains Plaggenborg.

Tepex with matrix of recycled polycarbonate



Bond-Laminates is continuously expanding its portfolio of materials to include sustainable fiber-reinforced composites. The focus here is on both the thermoplastic matrix and the reinforcing continuous fibers. The latest commercially available development is a Tepex variant based on recycled polycarbonate materials made from post-consumer waste. It meets all known requirements that were placed on the previous material formulation. “We are also working on using bio-based fiber and matrix systems and recycled carbon fibers,” explains Dr. Dirk Bonefeld, head of Marketing & Sales Consumer Electronics, Sports and Industry at Bond-Laminates.

Excellent flame-retardant properties



Another topic at the Bond-Laminates JEC World stand concerns Tepex applications in components for electric vehicles that require outstanding flame-retardant properties – such as carriers for electrical and electronics modules and battery cover plates. “As a result of its structure, Tepex has very good flame-retardant properties even without flame-retardant additives and it passes numerous flammability tests with good results,” explains Bonefeld. Nevertheless, the range also contains flame-retardant product variants based on polyamide and polycarbonate that fulfill the requirements, for example, of the flammability test as per US standard UL 94 (Underwriters Laboratories Inc.) with the top classification of V-0 with low wall thicknesses.

Capacity recently increased by around 50 percent



LANXESS has recently increased production capacity for Tepex in Brilon by around 50 percent. “In doing so, we are responding to the huge demand for our composite materials in the mass production of highly stressable components for lightweight vehicles and consumer electronics in particular,” says Bonefeld.

You can find more information about LANXESS products, developments, technologies and services that use polyamides, polyesters and thermoplastic composites for innovative vehicle concepts and particularly electromobility at https://new-mobility.lanxess.com and www.e-mobility.lanxess.com.

MORE ABOUT THIS TOPIC

PRESS RELEASE
Marcel Beermann.jpg

Marcel Beermann to head LANXESS’ Global Procurement and Logistics group function

April 08, 2020
PRESS RELEASE
LX05652 Bremspedal Porsche Taycan_5.jpg

First all-plastic brake pedal for battery-electric sports car

April 07, 2020
PRESS RELEASE
leaf_009164_Titel_A3.jpg

LANXESS suspends share buy-back

April 06, 2020
PRESS RELEASE
BMW_IMG_Tank_3292.jpg

Double-shell welded motorcycle tank

April 02, 2020
PRESS RELEASE
LX_03032.jpg

Perform with PerforMem

March 25, 2020
X
Usage of Cookies
We would like to use cookies to better understand you use of this website. This enables us to improve your future experience on our website. Detailed information about the use of cookies on this website and how you can manage or withdraw your consent at any time can be found in our Privacy Statement.

OK Other Settings