智数汽车大数据麦克恒通汽车轻量化在线
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[复合材料] 朗盛提供纤维增强热塑性复合材料用于轻量化汽车部件

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发表于 2013-10-18 09:09:42 | 显示全部楼层 |阅读模式
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Composite Sheets for Lightweight Vehicle Parts & more
Aug 14, 2013


LEVERKUSEN -- TEPEX is a registered trademark of Bond-Laminates GmbH, a LANXESS subsidiary based in the German town of Brilon. The thermoplastic composite sheets reinforced with continuous fibers manufactured here are sold under this brand name. This family of materials is already used to successful effect in automotive engineering, IT technology, sports equipment and electronics applications. Despite its very low weight, TEPEX combines impressive stiffness with outstanding strength. In many cases, it is far stronger than steel, aluminum and magnesium, for example.(TEPEX具有卓越的刚性和强度。在许多情况下,它远比钢、铝和镁的强度高) "Consequently, there are excellent opportunities for our high-performance composites in the large-scale series production of lightweight components for vehicles with low fuel consumption and emissions. Benefiting from short cycle times and very reproducible processes, it can be turned into three-dimensional components with great cost-efficiency. That's the big difference from other, mostly thermoset fiber composites with continuous fibers," says Dr. Christian Obermann, Managing Director of Bond-Laminates.
Structure – exceptionally stiff and strong in the fiber direction
Polyamide is the primary matrix for TEPEX in structural applications, but other thermoplastics such as polypropylene, thermoplastic polyurethane and polyphenylene sulfide are also used. (在结构应用上主要尼龙最为基体树脂,但是其它的热塑性塑料也用,如PP,PUR和PPS)The continuous fibers embedded in the matrix are fabrics made, for example, from high-strength glass, aramid or carbon fibers. (连续纤维包埋在基体树脂中,比如高强度玻纤、芳纶纤维或者碳纤维)They play a key role in determining the composite's mechanical properties. "The fibers are normally the same length as the component, which makes it very stiff and strong in the fiber direction," explains Obermann. At present, balanced or strong-chain fabrics are mainly used for reinforcement. The difference between them lies in the way the fibers are split in warp and weft directions and/or whether the fibers are distributed evenly or aligned in the same direction. What's more, grades of TEPEX based on alternative semi-finished textile products are currently being developed for component designs that are more appropriate for the loads to which they will be subjected.
Manufacture – fully impregnated and consolidated
For a long time, impregnating the fibers of semi-finished textile products with thermoplastic melts posed a major problem due to the high viscosities of these melts. Bond-Laminates have overcome this difficulty with a technological innovation in its special compression molding process. "We are now able to produce even large semi-finished composite products that are fully impregnated and consolidated in consistently high product quality in large-scale series production and optimize them to suit specific customer requirements," says Obermann.
Properties – stronger than steel or aluminum sheets
TEPEX has a density of just 1.4 - 1.8 kg/dm3. This makes it a much lighter alternative to steel or aluminum sheets with their densities of around 7.8 and 2.7 kg/dm3 respectively. Not only that, TEPEX can also be far stronger than these metal sheets. The "weight-corrected" specific strength of a polyamide 6 grade reinforced with 47 percent continuous glass fibers is 225 MPa/g/cm3, while steel and aluminum achieve values of around 50 and 120 MPa/g/cm3 respectively. Although its specific stiffness is slightly lower, this can largely be compensated using intelligent lightweight designs.
For example, back-injected TEPEX composites based on polyamide 6 are more than a match for plastic/metal composite technology based on sheet steel and polyamide 6. The composites are almost as stiff with double the strength and energy absorption. "In torsion tests, our composites are around 50 percent stiffer and some 65 percent stronger, because the material bond between the two plastics really comes into its own here," explains Obermann. Components made using these composites also absorb far more energy if they fail – irrespective of the type of load to which they are subjected.
Applications – well-established in the series production of automotive parts
TEPEX has demonstrated many times over that it is ideal for the series production of automotive components. For example, it is part of the hybrid design of a seat shell for a German automaker's sports coupé and is also used to impressive effect in the lower beam of the Audi A8's hybrid front end. What's more, the series launch of brake pedals and airbag housings based on hybrid technology incorporating TEPEX is imminent. "Hybrid technology with TEPEX has great potential as a cost-efficient alternative to carbon fiber-reinforced thermoset composites. The thermoplastic matrix offers significant advantages in terms of design freedom, shaping, welding, over molding, storage life and recycling," says Obermann. In addition to automotive parts, TEPEX is also used in items such as the soles of sports shoes, brake levers and pedals for racing bikes, rucksack frames, snowboarding and cycle helmets, and battery housings for smartphones.
About LANXESS
LANXESS is among the leading specialty chemicals companies with sales of EUR 9.1 billion in 2012 and roughly 17,400 employees in 31 countries. The company is currently represented at 50 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 as well as the Carbon Disclosure Leadership Index (CDLI).
Source: LANXESS
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