Lightweight design: First hybrid-molded rear bumper beam
One-shot molding technology enabled
Lightweight solution from German specialty Chemicals Company LANXESS has been featured in FCV (fuel cell vehicle) Clarity Fuel Cell, the latest model of hydrogen electric vehicle from Honda Motor Co., which recently has been introduced in the market. Using Tepex, continuous- and long-fiber reinforced thermoplastic composites with PA 6 matrix from LANXESS subsidiary Bond-Laminates, in combination with Durethan, a PA 6 high-tech plastic grade from LANXESS, Honda has introduced the world-first development of hybrid-molded rear bumper beam in the model using one-shot molding technology enabled by LANXESS.
“It is our great honor to feature our light weight solution with our Tepex and Durethan in Honda’s latest model of FCV,“ said Martin Klocke, Head of Technical Marketing and Business development Tepex Auto in the High Performance Materials business unit at LANXESS about the project.
The worldwide automotive industry is facing increasing restrictions on CO2 emissions and therefore automakers actively develop zero emission vehicles such as EV (electric vehicles) and FCV. These trends have been driving the demand for innovative materials and new technologies to make cars lighter. LANXESS has been offering lightweight solutions and technologies to the automotive industry which have proven themselves in various applications worldwide. This has resulted in developing a one-shot hybrid molding process for making large components out of its plastic and glass fiber composite. The result is approximately 50 percent weight reduction compared to the metal solution and a significant streamlining of the production process.
In the development, the materials are uniquely composed in several layers in combination with Tepex dynalite, continuous long glass fiber reinforced thermoplastic composite sheets, and Tepex flowcore, random long glass fiber reinforced composite sheets. This combination enables an easy material flow in the molding process to fill out complicated part geometry, and a greater mechanical strength with a superior characteristic of dynamic energy absorption in such a critical application as a rear bumper beam.