In an electric sports car, every gram of weight is important. According to foreign media reports, as the first mass-produced model in this field, the Porsche Taycan chose to be equipped with all-plastic brake pedals. This critical safety component was developed by BOGE Elastmetall GmbH in cooperation with the LANXESS High Performance Materials (HPM) business unit. Benefiting from the design of thermoplastic composite materials, the component has high mechanical strength and light weight. Its structure includes inserts made of Tepex dynalite material, LANXESS continuous fiber-reinforced thermoplastic composite materials and several webbing.
Dr. Klaus Vonberg, a lightweight design expert of HPM's Tepex Automotive Group, said: "This composite structure brake pedal is 50% lighter than similar steel structural parts. Based on the special fiber layer structure of Tepex inserts and local webbing reinforcement Can meet the demanding load requirements. Thanks to the widely used automation technology, this geometrically complex safety-critical component can achieve efficient and large-scale production. "
Tepex dynalite uses a thermoplastic substrate and is usually reinforced with a continuous layer of fiberglass fabric. This type of electric sports car brake pedal uses a PA6 base material composite structure, which contains an internal unidirectional fiber layer and a fabric layer with fibers arranged at a 45 ° angle on the two cover layers. The inner layer gives the assembly good tensile and bending strength.
The webbing is a thin plastic tape with a unidirectionally oriented high-strength continuous fiber system embedded in a thermoplastic substrate. Multiple fiberglass roving webbing is used in the brake pedal to reinforce the bottom surface of the component. Since the webbing and the Tepex insert are composed of mutually compatible plastic substrates, the webbing can be laser welded to the Tepex insert, resulting in a special laminate with fiber layers that strictly follow the load path and adapt to specific specific load components Claim. The cover layer of the insert and the 45 ° fiber layer are combined with the webbing on the top to ensure the high torsional strength of the pedal.
Dr. Daniel Hffelin of Boge Elastmetall Innovation Center said: "This special fiber layer structure, combined with organic sheets and webbing, can further reduce the weight of the brake pedal and achieve excellent mechanical properties." At present, based on the all-plastic version There are four different mass production brake pedal designs. In all component versions, the load path is optimized to accommodate various twisting directions.
When manufacturing brake pedals, the short-cycle hybrid molding automation process used is suitable for large-scale production. In this way, in the subsequent injection molding process, the overhanging Tepex insert and webbing are integrated. At the beginning of the production stage, an optical measuring system is used to precisely adjust the webbing and then position it on the Tepex insert to make them combined with each other. The component is first thermoformed and then back-molded with PA66 through an injection molding process.
In the field of electric vehicles, thermoplastic composite structures with customized fiber orientation are facing new development opportunities. According to Vonberg, "Application examples of Tepex inserts include: front-end systems and bumpers, brackets for electrical and electronic modules, trunk and spare tire compartments, battery housings and covers, structural components of the vehicle's" greenhouse "section and underbody protection The structural decoration of the battery. "
Another advantage of this type of composite design is that it causes less carbon emissions than metal structures. Thermoplastic composites are not only lightweight, but because of the use of hybrid molding methods, they can also integrate functions such as guides, brackets, and fasteners in a way that saves weight, energy, and cost. Unlike typical metal parts, this part does not require further processing, such as deburring or post-threading.
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