Potential applications of hybrid molding technology - cross-beam structures
Germany's LANXESS Specialty Chemicals has developed a mature lightweight structural component production method - plastic metal mixing technology This technology systematically combines the advantages of plastic and metal. For many years, LANXESS has been using this technology to manufacture automotive components such as front end, pedal boxes and brake pedals. This hybrid technology uses glass-reinforced nylon 6 (PA ) injection molding, while the use of steel or aluminum plate as a raw material in the metal parts. And this hybrid technology has now been extended by LANXESS to the manufacture of round or rectangular metal hollow profiles. Lukas schrer, Lightweight Structure Project Manager for the High Performance Materials Business Unit (HPM) explained: 'Compared with sheet metal, hollow profile has higher dimensional stability and stronger torsional strength and stiffness. And we believe that , This new 'hollow profile mixing technology' can produce parts such as cross-beams, but the use of traditional plastic-metal mixing technology can not make the product get enough flexibility.
LANXESS is adopting a cost-effective and one-step process, and the process faces many challenges. Boris Koch, a mixed-technology expert in technology application development for HPM's business sector, explained: 'It needs to be able to smoothly and automatically Inserts into injection molds. The dimensional tolerances caused by these metal inserts can damage the tool during production. If an undersized insertion hole in the tool system is present, this may be the result. ' In addition, In order to avoid cracking of the profile due to excessive melt pressure during injection molding, this process must allow the insertion of metal. Another challenge of this process is how to make a durable and properly shaped connection between plastic and metal. And Koch also introduced: 'We finally developed a process that is suitable for large-scale production. The process only requires investment in standard injection molds and machines. It can be produced just like standard injection molding, and the cycle time can be shortened. The entire production process It's as simple as the classic mixing technology of metal plates.'
In addition to crossing beams, this new hybrid technology also has great potential for the production of other structural components with higher mechanical requirements. Schröer said: 'As for light automotive components, we consider the structure of the seat, the front end, the tailgate and the frames on the truck. But at the same time we also saw this technology in the manufacture of furniture, ladders, and strollers. Potential. '
LANXESS provides custom-made polyamide compounds for injection moulding and mixing techniques for hollow moulding. Koch explained: 'This includes highly fluid material types for the production of complex shaped rib structures. With highly filled materials such as PA6, their excellent mechanical properties increase the structural performance of the hybrid part to a higher level. '
LANXESS is currently working on applying hybrid technology to simpler and more competitive die casting or extrusion molding.Even the hollow parts made of fiber-reinforced composite materials can use this new hybrid technology. This allows manufacturers to further reduce the weight of large-scale production of structural components. Said Koch.