• New series applications for Tepex in electric vehicles;
• Strong focus on sustainable composites for the circular economy and climate protection;
• Presentation of the bio-based Tepex Scopeblue;
• Composite materials for sport, leisure and consumer electronics.
“Using new series applications as an example, we want to underscore what opportunities our continuous-fiber-reinforced Tepex composites open up in the construction of highly stressable but lightweight structural components for electric vehicles,” explained Dr. Dirk Bonefeld, Head of Global Product Management and Marketing for Tepex at LANXESS.
In addition, the specialty chemicals company will be presenting a fully bio-based composite material based on flax and polylactic acid. The biocomposite is the first representative of the Tepex Scopeblue product series. It exemplifies the corporate strategy of decoupling the company’s production processes from fossil raw materials, conserving resources and establishing material cycles. Recycling of Tepex also contributes to this. “Thanks to its thermoplastic matrix, it is highly suited to reuse as quality-assured recycled compounds for injection molding. These compounds are already commercially available today,” explains Bonefeld.
Lightweight design with functional integration
LANXESS will be showcasing a front-end support and a battery tray as series applications of Tepex in electromobility at JEC. The front-end support is being installed in the new luxury sedan from a US manufacturer of electric vehicles. The torsionally stiff structural component is manufactured by the hybrid molding process using the polypropylene-based Tepex dynalite 104-RG600. It is significantly lighter than a metal construction and exhibits excellent crash performance. “The injection molding stage of the hybrid molding process immediately integrates numerous functions in the component such as mounts and guides, which noticeably reduces the subsequent effort involved in assembly and the manufacturing costs,” says Bonefeld.
The battery tray belongs to a fully electric luxury vehicle from a car manufacturer based in southern Germany. The component is based on polyamide 6 and is also produced via hybrid molding using Tepex dynalite 102-RG600 and the highly reinforced compound Durethan BKV60H2.0EF. According to Bonefeld,“Tepex was the material of choice because it is inherently flame-retardant, unlocks potential for lightweight design and provides opportunities for functional integration. In addition, the insert made from Tepex does not need to be protected from corrosion unlike an equivalent made from sheet steel.”
Large-format housings for high-voltage batteries
Large plastic housings for high-voltage batteries also represent a potential application for Tepex in electric vehicles. Together with the company Kautex Textron, a close-to-production technology demonstrator has been developed for this, with LANXESS responsible for material and Kautex for component and process development. “The component,” says Bonefeld,“manages without any metallic reinforcements. It demonstrates the advantages of thermoplastics over metals in terms of weight and cost reduction, functional integration, and electrical insulation properties.”
Sustainable, lightweight and boasting high mechanical performance
The new Tepex Scopeblue biocomposite is particularly lightweight thanks to the low density of the reinforcing continuous flax fibers. Its weight-specific stiffness is comparable to that of the equivalent glass-fiber-reinforced material variants. It can be produced to a level of quality suitable for large-scale production. “We see possible applications in sporting goods, interior parts for cars and housing components for electronics,” says Bonefeld.
Besides Tepex variants made from biological raw materials, LANXESS is working intensively on a number of recycling concepts for its composites. “In addition, we are producing life-cycle analyses for Tepex so that users can precisely identify the carbon footprint of their component,” explains Bonefeld.
Recyclable alternatives to SMC
Another focus area for LANXESS at JEC (jec-world.events) is that of new Tepex Flowcore composites for compression molding. They are a recyclable and far more ductile alternative to thermoset sheet molding compounds (SMCs). Possible uses include load compartment wells, underbody paneling components and battery covers.
Besides cars, key application areas for Tepex are consumer electronics, sport and leisure. At JEC, LANXESS will be presenting the world’s first carbon smartphone, an ultra-thin and ultra-lightweight electric skateboard and an extremely lightweight running shoe as exhibits from these areas.
JEC World will take place from May 3 to 5, 2022, at the Paris Nord Villepinte Exhibition Centre. You can find LANXESS at booth N33 in hall 5.
You can find more detailed information about Tepex at tepex.com/.
LANXESS (lanxess.com) is a leading specialty chemicals company with sales of EUR 6.8 billion in 2019. The company currently has about 14,400 employees in 33 countries. The core business of LANXESS is the development, manufacturing and marketing of chemical intermediates, additives, specialty chemicals and plastics. LANXESS is listed in the leading sustainability indices Dow Jones Sustainability Index (DJSI World and Europe) and FTSE4Good.
This company release contains certain forward-looking statements, including assumptions, opinions, expectations and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of LANXESS AG to differ materially from the estimations expressed or implied herein. LANXESS AG does not guarantee that the assumptions underlying such forward-looking statements are free from errors, nor does it accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecast developments. No representation or warranty (expressed or implied) is made as to, and no reliance should be placed on, any information, estimates, targets and opinions contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and accordingly, no representative of LANXESS AG or any of its affiliated companies or any of such person's officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.