Glass Fiber Reinforced Composite for Mercedes-Benz S-class Cabin
The trunk shaft of a Mercedes-Benz S-Class must safely accommodate the 48-V on-board power battery. Lanxess TePEx Dynalite continuous fiber-reinforced thermoplastic composites are now used in place of metals to make structures 30% lighter while still handling mechanical stresses placed on parts. The strength of the composite material will prevent the battery from passing through the compartment in the event of a collision and prevent fluid from flowing in and out of the area.
Using a hybrid molding process, the billet is made of polyamide 6-based Tepex Dynalite and reinforced with two layers of continuous fiberglass fabric. Lanxess polyamide 6 Durethan is injected to strengthen and harden the assembly. Stamping parts are used to form parts and prevent breakage of composites. Lanxess uses advanced calculations to simulate the overhang process, enabling it to identify the water cutting process and analyze potential weaknesses in the tool. Rounding and orientation of continuous fibers in the load cabin are also simulated, which improves manufacturing accuracy and helps predict the mechanical properties of parts. These detailed steps can add up to huge savings in time and money.
"If there is a collision, the battery will not penetrate or damage the wall of the groove in any way," explains Klaus Vonberg, PhD, Lanxess Tepex applications specialist. The high strength and stiffness of our fabric-based composite ensures this, and the composite design also ensures the tightness of the loading chamber to prevent the entry and exit of fluids such as water and battery electrolyte."
"We also see great potential for electric vehicles -- so for safety devices, complete battery system housings or devices used to load components under the 'hood', our lightweight structural materials, which are much lighter than metal, can reduce costs and help mass production of electric vehicles," Added by Dr. Von Berg.