ET Polymers|April - May 2020
In a battery-electric sports car, every gram of weight counts. That is why the first mass-production vehicle in this segment is using an all-plastic brake pedal. This safety-critical component has been developed by Boge Elastmetall GmbH, a global provider of vibration technology and plastics applications for the automotive industry, in close cooperation with the Lanxess High-Performance Materials (HPM) business unit. It owes its high mechanical strength and very low weight to a thermoplastic composite design. Its structure comprises an insert made from Tepex dynalite, a continuous-fiber-reinforced thermoplastic composite from Lanxess, and several tapes.
“The composite structure makes the brake pedal 50 percent lighter than a comparable steel design. The structural component meets the demanding load requirements thanks to the tailor-made fiber-layer construction of the Tepex insert and additional local tape reinforcement. Extensive automation allows the geometrically complex safety-critical component to be manufactured efficiently and in a way that is suitable for large-scale production,” explains Dr. Klaus Vonberg, an expert in lightweight design at HPM’s Tepex Automotive Group.
Precise combination of fiber layers arranged in various orientations
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April - May 2020