www.green-mobility.com

Efficient lightweight design can reduce opera-ting costs as well as emissions.

New requirements significantly increase the average weight of a vehicle.

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LANXESS is a leading specialty chemi-cals company with sales of EUR 8.8 billion in 2011 and 17,100 employees in 31 countries. The core business of LANXESS is the development, manufac-ture and marketing of plastics, rubber, intermediates and specialty chemicals. LANXESS is a member of the lead-ing sustainability indices Dow Jones Sustainability Index (DJSI) World and FTSE4Good.

State-of-the-art electric motors and hybrid engines weigh significantly more than conventional internal combustion engines. This alone is reason enough for LANXESS to push forward with research and development initiatives that can mitigate the expected weight increase of vehicle fleets through intelligent lightweight design inno-vations. This will help reduce op-erating costs and CO2 emissions.

L osing weight pays off – espe-cially in vehicle manufactur-

ing. Lighter vehicles consume less fuel. This means that in view of ris-ing energy costs and increasingly stringent emissions limits, vehicles must be designed as light as pos-sible. However, increased require-ments concerning workmanship and equipment have led to a continuous increase in the average weight of vehicles. As a result, car manufactur-ers are now willing to pay up to 20 Euro per kilogram of weight reduc-tion. LANXESS has accepted the challenge. As a pioneer in “Green Mobility”, we are developing prac-tical lightweight design solutions that enable manufacturers to build lighter yet stronger vehicles. Today, LANXESS provides innovations that

reduce per kilo production costs and make lightweight design solutions viable for high-volume production. Advanced high-performance plastics and hybrid components are key to this development. In addition to reducing

vehicle weight, fuel consumption and emissions, they also reduce energy consumption and related produc-tion costs during manufacture. As a result, the environment, drivers and industry all benefit.

X-Lite® Leather weighs up to 20 % less than conventional lea ther yet is equally wear- re sistant. Advanced Tepex® in-lays made of thermoplastic composites (moldable fiber-rein-forced plastic panels) help man-ufacturers reduce the weight of car seats by up to 50 % when compared to seat designs con-structed from plastic alone.

Advanced high-tech plastics can be used to replace metal components and reduce weight. They are rust-proof, extremely moldable, enable new design concepts and allow for the better integration of other

Lightweight design methods com-bine lightweight components and innovative concepts. Plastic / metal hybrid technology from LANXESS combine materials like high-tech plastics with steel or aluminum.

components . Depending on the area of application, the requirements for car parts and the materials they are made of can vary. Thus, it is crucial to choose the appropriate material for any individual application.

This ensures that appropriate levels of strength and weight reduction are achieved throughout the component. Compared to all-steel components, weight reductions of up to 50 % can be achieved using such technologies.

If vehicle weight is reduced by 100 kg through lightweight design,

Significantly lighter pedals provid-ing the same strength as conven-tional steel pedals: Thermoplastic composites (Tepex®) and ribbed structures made of polyamide (Durethan®) enhance the load-bearing capacity of the pedals in comparison to steel pedals and save up to 50 % in weight.

Roof frames are 30 % lighter when made with plastic / metal hybrid technol-ogy, yet cost just the same.

Timing belts made of high- performance rubber are not only significantly lighter, they also ex-tend the service life and increase the efficiency of engines.

A plastic and fiber spare tire well reduces weight and increases functionality. The nine kilogram spare tire well made of highly filled plastic with 60 % glass fiber is attached directly to the body frame. It stores the spare tire and onboard tool kit and also stiffens the rear section of the vehicle.

Depending on the vehicle type, hybrid front ends made of plastic / metal composites can reduce weight from 10 % – 40 % compared to front ends made of metal alone. By integrating thermoplastic composites, up to 20 % in vehicle weight can be saved additionally in comparison to sheet aluminum solutions.

Tepex® hybrid technology allows for a much thinner design for airbag housing side walls thanks to thermoplastic composites that do not compromise on stiffness or strength. Thus, the weight of airbag housings can be reduced by roughly one-third.

Polyamide materials (Dure-than®) are super light and moldable. Polyamide oil pans for engines and transmissions can be manufactured with out the need for re-machining. They allow for the cost-efficient inte-gration of functions – while re-ducing weight by up to 50 % in comparison to steel solutions.

250 kgElectriccar

50 kgCombustion

engine

100 – 150 kgHybrid vehicle range extender

26.00650 kg 1,070 kg

150

11.30

9.90 40

8.60 20

Operating costs per 100 kmin Euro

CO2 emissions per person

in g / km

Example: Mini

1959 2006

1 suitcase = 25 kg

380

motorists can save up to 5 liters of fuel for every 1,000 km they drive.

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Advanced materials provide greater efficiency and reduce fuel consumption.

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