• Material solutions for reduced CO2 emissions;
• Cost-effective processing in large-scale series production.
At the VDI conference “Plastics in Automotive Engineering” in Mannheim, LANXESS will showcase tailor-made high-tech thermoplastics for sustainable mobility. These will focus in equal measure on gasoline-, diesel- and gas-driven cars as well as electrical and hybrid vehicles. “Whether it’s in drive system, lightweight design or electrical and electronic systems, our innovations are designed to improve the efficiency and performance of vehicles, enabling a reduction in CO2 emissions and thus making the vehicles more environmentally friendly. At the same time, our materials provide cost-effective component solutions that are suitable for large-scale series production,” explains Martin Wanders, head of global applications development in the High Performance Materials (HPM) business unit at LANXESS.
Series-tested lightweight design using thermoplastic composite sheets
In Mannheim, LANXESS will use the example of a battery console for vans to highlight the incredible potential that the Tepex brand of continuous-fiber-reinforced semi-finished thermoplastic composites offers for the lightweight design of highly load-resistant components. The console is created using the DLFT process (Direct Long Fiber Thermoplastic), with Tepex as reinforcing overlay. “Thanks to Tepex, the component passes a more stringent crash test both in freezing conditions and at high temperatures unlike a previous DLFT design using a different reinforcing material,” says Wanders.
A sports car seat shell manufactured using Tepex will also be used to demonstrate the benefits of hybrid molding. In this process, semi-finished composites are both formed and overmolded in an automated one shot process in the injection mold. “The highly integrated component is considerably more lightweight than a metal component solution while giving the same performance. It also provides a lower, more sporty seat position for the driver,” explains Wanders.
New hydrolysis-stabilized PBT grades for vehicle electronics
Another key area for LANXESS is hydrolysis-stabilized PBT compounds for automotive electrical and electronic systems and new, thermally conductive polyamides. One material innovation, for example, is the hydrolysis-stable and extremely flame-retardant grade Pocan BF 4232 HR. “The compound achieves outstanding results in all the colors tested in the UL 94 flame retardance test of the U.S. testing organization Underwriter Laboratories, making it ideal for components in electric drive systems, for instance,” explains Wanders.
First applications for thermally conductive polyamides
LANXESS will be using the example of a motor flange for a car internal ventilation drive to show the benefits of the thermally conductive Durethan BTC 75 H3.0 EF polyamide 6. “This material conducts heat approximately five times better than a standard polyamide 6 with 30 percent glass fiber reinforcement and is an alternative to polyamide 6 compounds with aluminum oxide or boron nitride as heat-conducting filler,” explains Wanders.
New to the range polyamide 66 with 60 percent glass fibers
LANXESS will also present a highly reinforced polyamide 66 with 60 percent glass fibers. Wanders: “Durethan AKV 60 XF exhibits exceptionally high stiffness and strength, brings an outstanding high long-term service temperature and is still easy flowing, despite the filler content. It exhibits great potential for replacing metal, particularly for structural components that are subject to high dynamic stress.”
LANXESS (lanxess.com) is a leading specialty chemicals company with sales of EUR 8.0 billion in 2014 and about 16,300 employees in 29 countries. The company is currently represented at 52 production sites worldwide. The core business of LANXESS is the development, manufacturing and marketing of plastics, rubber, intermediates and specialty chemicals. LANXESS is a member of the leading sustainability indices Dow Jones Sustainability Index (DJSI World) and FTSE4Good.