Shanghai, March 25, 2020-Tepex continuous fiber-reinforced thermoplastic composites from specialty chemicals company LANXESS have great application potential in many fields, including lightweight structural safety components. The child seat headrest developed as a technology demonstration is manufactured by the particle foam composite injection molding process, which fully demonstrates the technical advantages and application prospects. 

"Compared with other components produced commercially, the insert made by Tepex can effectively reduce the weight of the headrest by 30%, ensuring excellent crash resistance and simplifying the production process." LANXESS High Performance Materials (HPM) Business Unit Tepex Experts from Lightweight Structure of Automobile Group introduced.

Government funded project

This technology demonstration product is the result of a multinational research project funded by the German Federal Ministry of Economics and Energy as part of a central innovation plan to support SMEs. Participants in the project include the School of Lightweight Structures and Polymer Technology (SLK) at Chemnitz University of Technology, Polycomb GmbH in Ornlund, Thuringia, and Avionaut, a child seat manufacturer in Szarlejka, Poland Chair as a reference product).

Efficient production process

In order to manufacture the headrest, the project partners developed an alternative production process based on PCIM. To reinforce the headrests at various locations while reducing weight, they used custom inserts made from Tepex dynalite 104-FG290 (4) / 47%, a polypropylene-based composite material reinforced with two layers of continuous glass fiber roving. Using an injection tool with a steering plate, the insert is manufactured by a (one-step) process, and the short glass fiber reinforced polypropylene compound is reversely injected to integrate the support structure such as the headrest and backrest. Then, the preformed inserts are reverse foamed in the second tool using particulate foam based on expanded polypropylene (EPP).

Reduced the number of parts from six to one

In contrast, most headrests currently use multiple independent parts for mass production. The support structure is made of long glass fiber reinforced polypropylene, and then four polypropylene support pins are assembled with separately foamed EPP parts. "The highly integrated new production process is not only more energy-efficient than the previous process, but it can also directly produce finished parts. This can reduce the total number of parts from six to one, thereby reducing logistics production costs and machine costs. , "Norbert Schramm, scientific assistant and head of the ZIM project at Chemnitz University of Technology, introduced. Current fiberglass headrest components can reduce weight by about 26%, and there is still potential for further weight loss. Schramm said: "If you use carbon fiber reinforcement in semi-finished composite materials and injection molding materials, the weight of the assembly will be reduced by nearly 30%."

Close co-opperation

Project partners have different development priorities and tasks. For example, SLK is responsible for selecting materials, analyzing composite adhesion, designing structures and performing topology optimization; Polycomb ’s responsibilities include product development and design, prototype production, and system concept optimization; Avionaut is responsible for analyzing load distribution, studying design structures, and In the actual crash test, the impact performance of the headrest and the entire seat was detected; LANXESS helped the project partners to select materials and assisted in the development of the hybrid molding process.

Great application potential, including other assemblies

LANXESS foresaw the broad application prospects of Tepex materials and new production processes, such as baby carriers, backrests and armrests, self-driving car seat shells with a new complex seating concept, and comfortable seats for shuttle buses, VIP buses and family buses shell. Lightweight seats are particularly beneficial for electric vehicles. "As part of HiAnt customer service, we help project partners develop and apply such components and related processes. Our services include drape simulation, tool design, and processing techniques after Tepex inserts become soft and heated. We also support mass production processes. Implementation, "Vonberg said.

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