LANXESS introduces hollow profile hybrid technology with greater torsional stiffness and strength

LANXESS is currently introducing its hollow profile mixing technology to the market
.
Using this new lightweight design technology, metal hollow profiles can be functionalized on conventional injection machines using plastic mixtures, resulting in plastic-metal composite parts that are more efficient than previously functionalized hollow profiles using other technologies in terms of greater torsional stiffness and strength
.

Demonstration parts produced by LANXESS using hollow profile hybrid technology have high torsional stiffness and strength (image courtesy of LANXESS)

"Hollow profile mixing technology has now reached a very good level, and we have carried out various development project studies together with our customers, some of which have reached the prototype stage
," explains Dr.
Matthias Theunissen, expert in lightweight design at LANXESS
.
Potential applications for this technology in the automotive industry include beams, connecting rods, stabilizers and seat components
.
In addition, the new lightweight technology can be used to manufacture ski poles and trekking poles, as well as components for the furniture and construction industries
.

Simple injection molding technology, short cycle times

The hollow profile hybrid technology is a further development of the conventional plastic-metal composite technology (hybrid technology) with sheet metal
.
The advantage of this new technology is that processors can achieve production with short cycle times, which is typical of injection molding technology for high-volume production, and as a result, the production process is efficient and economical
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The cost of investing in this technology is lower as no auxiliary equipment or tooling technology is required
.
In addition, the ability to use affordable hollow profiles with relatively large dimensional variations also contributes to the cost-effectiveness of the overall process
.

“With the help of innovative tolerance management, we were able to prevent this profile from damaging the mold or preventing leakage in the injection mold,” explains Theunissen
.
When overmolding thin-walled hollow profiles with molten resin, the inside of the mold cavity High pressures in excess of 400-500 bar are usually generated, which brings the risk of deformation or destruction of the profiles
.
“For this, we have optimized the process so that the profile can withstand the pressure created in the mould cavity without having to support it from the inside,
” says Theunissen
.

Reduce the weight of the car beam by 30%

For the hollow profile mixing technology, LANXESS offers highly reinforced polyamide 6, such as the easy-flowing Durethan BKV60H2.
0EF DUS060, which contains 60% by weight of short glass fibers
.
With their high strength and rigidity, these compounds can further improve the performance of the corresponding components
.
In a simulation study, LANXESS investigated how the use of these compounds in the design of automotive crossmembers can benefit
.
“We can design parts that are about 30 percent lighter than an all-steel structure, while providing better mechanical properties in some areas,
” Theunissen said
.

LANXESS estimated typical load cases and component characteristics, such as the vibration behavior and stiffness of the steering wheel in the direction of gravity
.
This part also highlights the great potential of this technology for low-cost integration of functions, such as connecting the A-pillar, as well as installing the steering column, instrument panel, weather-resistant controls and airbags, all by direct injection.

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High-quality forecast simulation

LANXESS has developed new computational models for hollow profile mixing technology based on simulation tools that have proven their success in traditional mixing technology applications over the years
.
In this way, the production process, as well as the quality of the connection between metal and plastic, can be precisely predicted
.
“For example, we can use these tools to accurately predict the maximum stress that hollow-section hybrid components can withstand and the point at which they will fail
.
We use this expertise in our work with customers,
” explains Theunissen
.

Using its simulation tools, LANXESS is able to accurately predict the maximum stress that a hollow section hybrid component (such as the car crossmember in the left screen) will experience and the point at which failure will occur (image courtesy of LANXESS)

Using a newly developed sample, LANXESS verified the simulation results
.
Extensive testing on real components under static and dynamic loads confirmed the simulation results
.