Smart Molding International 4-2021

molding technologies 38 smart_molding international 4/2021 T epex dynalite continuous-fiber- reinforced thermoplastic com - posite materials are increasingly being used as an alternative to metal in light-weight design. One new ap - plication for these composites from LANXESS is in the manufacture of the load compartment well installed in the Mercedes-Benz S-Class for accommodating the 48V on-board power supply battery. The compos - ite components can withstand high mechanical stresses and are around 30% lighter than comparable sheet metal components. “In the event of a crash, the battery must not penetrate or in any way damage the recess wall. This is ensured by the high strength and stiffness of our fabric-based com - posite material,” says Dr. Klaus Von - berg, an application expert for Tepex at LANXESS. “The composite design also ensures that the load compart - ment well is leaktight, preventing the ingress and egress of fluids like water and battery electrolyte.” Cost-cutting functional integration The safety component is manu - factured economically in a hybrid molding process using a blank that is around 110 x 80 centimeters large produced by a water cutting machine. The blank is made from polyamide-6 -based Tepex dynalite 102-RG600(2), which is reinforced with two layers of continuous-glass-fiber fabrics. The easy-flowing polyamide 6 Durethan BKV60H2.0EF DUS060 from LANXESS is used as a back-injection material for the cost-saving integration of fasten - ers, but also of reinforcing ribs. Sixty percent of its mass comprises short glass fibers, which also make it ex - tremely strong and stiff and a perfect match for the Tepex. Complex forming process Forming (draping) of the blank is performed by a stamp and is a highly complex process, among other things due to the high draw ratios. This is be - cause the composite material does not • On-board power supply battery remains firmly secured even in case of a crash • Lighter than sheet metal • High degree of strength and stiffness • Precision forming of the large-format composite insert Lightweight load compartment well for luxury sedans