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Every gram of a component counts for an electric sports car, which is why the first mass-produced sports car with a fully plastic brake pedal was born
.
The safety component was developed by the LANXESS High Performance Materials (HPM) business unit in conjunction with the international supplier BOGE Elastmetall, which supplies vibration damping systems and plastic components for the automotive industry
.
“The custom fiber structure of the Tepex inserts, reinforced with multiple layers of moldings, makes the brake pedal 50% lighter than comparable steel products, while meeting higher load requirements
.
An all-plastic brake pedal for a battery-electric sports car whose structure includes inserts made of LANXESS Tepex dynalite, a continuous fiber-reinforced thermoplastic composite
.
Precise combination of multidirectionally aligned fiber layers
Precise combination of multidirectionally aligned fiber layersTepex dynalite is a fully integrated semi-finished product whose thermoplastic matrix material is usually reinforced by multiple layers of continuous glass fibers
.
Ribs are thin strips of plastic constructed of unidirectionally aligned high-strength continuous fibers that are embedded in a thermoplastic matrix
.
Mass production of four brake pedals
Mass production of four brake pedals"This tailored fiber layer structure, combined with organic sheets and ribs, promises to further reduce the weight of the brake pedal while achieving the excellent mechanical properties it needs to achieve," says Dr.
Daniel Häffelin from the BOGE Elastmetall Innovation Center
.
One-shot molding with Tepex
One-shot molding with TepexThe brake pedal is manufactured by a one-time hybrid molding process, which has a short cycle and is suitable for large-scale mass production
.
High-strength structural components for electric vehicles
High-strength structural components for electric vehiclesThe combination of thermoplastic composite structures and oriented fibers brings new opportunities in the field of electric vehicles
.
"Tepex inserts can be used in front-end brackets and bumpers, electrical and electronic module brackets, luggage compartments and spare wheel wells, battery covers, structural components in the 'greenhouse' part of the vehicle, and protective structures for batteries under the body," said Dr.
Vonberg
.
The low carbon footprint compared to metal-structured components is also one of the reasons for the use of Tepex and molding composite structures
.
Thermoplastic composites are not only lighter than comparable materials, but also use a hybrid molding process that saves weight, energy, and cost because it integrates guides, brackets, and fasteners
.
The use of thermoplastic composites eliminates the need for time-consuming further processing of metal parts such as polishing or subsequent tapping
.
