The Tepex continuous-fibre reinforced thermoplastic composites from LANXESS are ideal for the production of structural components that form part of driver assistance systems. High tensile strength under long-term dynamic stress. Installation and logistics are simplified as a result of functional integration. Unlike metal alternatives, there is no chance of a short circuit.
LANXESS Tepex continuous-fibre-reinforced thermoplastic composites are suitable for the manufacture of structural components for driver assistance systems. A bracket for a battery, for example, delivers electricity to the Mercedes-Benz S-highly Class’s automated driver assistance system “Intelligent Drive” in the event of a power outage.
Poeppelmann Kunststoff-Technik GmbH & Co. KG in Lohne, Germany, manufactures the bow-shaped bracket from Tepex dynalite 104-RGUD600(4)/47 percent polypropylene. The manufacturing method is a two-stage process that combines composite shaping (draping) and injection moulding.
“Because of the composite construction, the completed product can be up to 40% lighter than a metal version,” explains Joachim Schrapp, a lightweight design expert at Poeppelmann. “The injection moulding step also allows for the integration of functionality that not only make installing the bracket easier, but also reduce the logistical workload.” All of this helps to reduce production costs.”
Optimized distribution of forces
The bracket’s function is to clasp the battery – which weighs roughly 10 kilos – firmly in place in the vehicle’s rear compartment, even when subjected to the high acceleration forces experienced in a crash. The bracket is designed to ensure that the majority of the forces are passed from the points of application to the composite material’s continuous glass fibres. This takes advantage of the Tepex blank’s high strength and rigidity.
“Unlike fibre-reinforced injection-moulded composites, for example, our composite does not creep under high sustained pressures and so does not distort,” says the researcher. According to Philipp Maas, sales and project manager for Tepex at LANXESS, “this ensures that the battery is retained in place permanently.” The blank also has a high fatigue strength, which means it won't become brittle and shatter over time as a result of frequent or heavy vibrations like those caused by potholes.
Corrosion-resistant and electrically insulating
Another advantage of the composite semi-finished product is that it is corrosion-resistant, making transportation and storage much easier than with metal coils. The electrical properties of the structural material are also important. “It is electrically insulating to the battery’s body and metal components, reducing the chance of short circuits greatly. A component made of metal, on the other hand, would necessitate additional safeguards against short circuits,” adds Schrapp.
