lanxess introductionsunny-plastic.com/upload/201703/03/201703031332006666.pdf · 2017. 3. 3. ·...

LANXESS Introduction, Overview June 3, 2008 Thomas Babl

LANXESS Introduction

LANXESS IntroductionPolyamide 6, 66 (Durethan®) and PBT (Pocan®)

June 3, 2008

Thomas Babl – LANXESS Hong Kong


Agenda

1. LANXESS – Who we are

2. Material Introduction

3. Application Development Support

3.1 CAE & Design Support

3.2 R&D Thermoplastic Testing Center (RDTC)

3.3 Part Approval Testing Capabilities

4. Customers we serve

5. Technology Examples, Case Studies

5.1 Structural Inserts for Body-In-White

5.2 Applications under the Hood (UTH)

5.3 Exterior Parts

5.4 Structural Plastic-Metal-Hybrid Parts


Agenda

1. LANXESS – Who we are2. Material Introduction









5.3 Exterior Parts



Bayer Health CareBayer Crop Science

Bayer Material ScienceBayer Chemicals

Spin-off

Bayer Health Care

Bayer Crop Science

Bayer Material Science SCP – Semicrystalline PlasticsSTY – Styrenics

Engineering Plastics

Chemicals

Performance Rubber

Listing 01/05


Spin-off

LANXESS Introduction, Overview June 3, 2008 Page 7 Thomas Babl

Employees worldwide

Global orientation

Approx. 17,036

Over 50 companies50 locations18 countries

Competitive situation approx. 70 % of sales with top positions

Few Facts and Figures about LANXESS

LANXESS is one of the most important providers of polymers and chemicals globally

Sales in 2006 Approx. 7 Billion Euro turn over


CamacariIsithebe

ThaneBaroda

Map Ta Phut

Qingdao

Toyohashi

Brunsbüttel

Leverkusen

Mannheim

Filago*

Tarragona

PortJérôme

Uerdingen*

Dormagen

Antwerpen

Marl

Chardon/OH

Sarnia/Canada

Newark/OHAddyston/OH

Bushy Park/SC

Orange/TX

Lerma

Bitterfeld

Porto Feliz

Zarate

Ede

Vilassar de Mar

RustenburgSydney

Wuxi* 無錫

Baytown/TX

LaWantzenau

Branston

Zwijndrecht

Production SitesSCP Plant Locations

Hamm-Uentrop


Agenda


2. Material Introduction3. Application Development Support








5.3 Exterior Parts



Durethan is the trade name of Lanxess for its range of engineering thermoplastic materials based onPolyamide 6, Polyamide 66, and their Copolymers.

• Pocan is the trade name of Lanxessfor its thermoplastic polyesters based on Polybutylene Terephthalate (PBT)

Polyamide and Polybutylene Terephthalate belong to semi-crystalline polymers offering an excellent combination of mechanical and electrical properties coupled with good resistance to heat and chemicals.

LANXESS Portfolio: PA6, PA66 (Durethan®), PBT (Pocan®)


Typical Applications in LANXESS Durethan®

Durethan (PA6, PA66, Co-PA, amorphous PA)

Electro/ Electronics Sports and Leisure

Packaging

ToolsAutomotive


Typical Applications in LANXESS Pocan®

Pocan (PBT, PBT+PET, PBT+ASA, PBT+PC)

Electro/ ElectronicsAutomotive


Agenda



3. Application Development Support3.1 CAE & Design Support







5.3 Exterior Parts



1. Concept studies2. CAE analysis3. Design support to system supplier4. Productivity Improvement Tools5. Material Evaluation&Development

6. Part Testing

7. Launch Support

8. Training, Introduction

Lanxess Application Development Support Overview

Added Value & Joint Success


Moxi (STY)

Turin, Italy

Leverkusen, GermanyParis, FrancePittsburgh, USA

Detroit, USA

Application Development Support, Global FootprintSemicrystalline Products Technical Center and CAE Facilities Worldwide

Hong Kong

Tokyo

Seoul

Hong Kong: Application Development, CAE Services Regional HQ

Seoul, Tokyo: Application Development, CAE Service Center

http://feainformation.com/cgi-bin/tracker.cgi?l=ANSYS-INC

http://feainformation.com/cgi-bin/tracker.cgi?l=LSTC


Agenda




3.1 CAE & Design Support3.2 R&D Thermoplastic Testing Center (RDTC)






5.3 Exterior Parts



CAE & Design Support

Finite-Element Analysis

• Rheological FE-Analysis (Moldflow)

– Filling pattern (optimizing machine size and surface qualitiy)

– Glass fiber orientation– Shrinkage and warpage– Cooling system and cycle time

improvement• Mechanical/Fluid FE-Analysis

– Thermal expansion– Stiffness and strength– Creep– Impact simulation– Dynamical behaviour– Noise– Fluid Dynamics

Part design• Development of detailed solutions• Material optimized design• Incorporation of FE-results into

design• Investigation of joining alternatives

Tool design• Gate design• Hot runner systems• Stiffness of tool• Demolding techniques

Part and Mold Design


Agenda




3.2 R&D Thermoplastic Testing Center (RDTC)3.3 Part Approval Testing Capabilities





5.3 Exterior Parts



R&D Thermoplastic Testing Center

New Building, 2nd and 3rd floor: 350 m2, thereof humidity controlled: 175 m2.

LANXESS (Wuxi) Chemicals Company

簡報者

簡報註解

Überschrift übernommen


R&D Thermoplastic Testing CenterLab Design May 2007

簡報者

簡報註解



R&D Thermoplastic Testing CenterEquipment

簡報者

簡報註解



Agenda





3.3 Part Approval Testing Capabilities4. Customers we serve




5.3 Exterior Parts



Mechanical Testing:• Shaker Tests• Drop Tests• Tensile Tests (Static and

Dynamic)

Rheological Measurements:• MFR, MVI

Special Test Equipment:• Heat Aging• Media Aging• Burst Pressure Tests

Prototype Production:• Specimen Production• Device Construction

Microscopy:• Atomic Force Microscope (AFM)• Light Microscope

Service on Part TestingPortfolio


Pendulum TestFalling Rock TestsOil Pan

Head-Impact-Tests

Tensile testHybrid frontend

Headrest Bracket

Climate Chamber

Pendulum TestsHybrid Bumper Beam

Service on Part TestingMechanical Testing


Shaker TestsEGR-Tests

Leakage, Media- and Thermal Aging

Burst Pressure (Backfire- Test)

Climate Chamber

Pressure Cycle Test

Service on Part TestingTesting of Parts under the hood (UTH)


Agenda







4. Customers we serve5. Technology Examples, Case Studies



5.3 Exterior Parts



Auto Industry OEM Customers

http://images.google.com.sg/imgres?imgurl=http://www.rovertorque.co.uk/images/zRover_Logo.jpg&imgrefurl=http://www.rovertorque.co.uk/free.html&h=600&w=800&sz=30&tbnid=oer-ZL4O7WEJ:&tbnh=106&tbnw=141&prev=/images%3Fq%3Drover%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=1

http://www.mazda.com/

http://images.google.com.sg/imgres?imgurl=http://www.meso.net/projects/the_virtual_goalie/images/opel-logo.jpg&imgrefurl=http://www.meso.net/projects/goto.php%3Fthe_virtual_goalie&h=266&w=354&sz=9&tbnid=DIZD2kinUDIJ:&tbnh=87&tbnw=117&hl=en&prev=/images%3Fq%3Dopel%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.trfc.com.sg/images/sponsor_logos/big-hyundai-logo.gif&imgrefurl=http://www.trfc.com.sg/sponsors/index.php&h=199&w=300&sz=10&tbnid=voDKdgNoJSwJ:&tbnh=73&tbnw=111&prev=/images%3Fq%3Dhyundai%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://oldautoads.homestead.com/AutoLogos/AutoLogos2/kia_logo2.gif&imgrefurl=http://oldautoads.homestead.com/&h=198&w=200&sz=22&tbnid=9dHU56j6744J:&tbnh=98&tbnw=99&prev=/images%3Fq%3Dkia%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=1

http://images.google.com.sg/imgres?imgurl=http://home.aland.net/ma22004/bilder/Big%2520bilder/peugrot/Peugeot_logo.jpg&imgrefurl=http://home.aland.net/ma22004/album.htm&h=300&w=300&sz=11&tbnid=cNY4x-KQGp0J:&tbnh=111&tbnw=111&prev=/images%3Fq%3Dpeugeot%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.miceed.org/freeze_pro/images/GM_Logo.jpg&imgrefurl=http://www.miceed.org/2005conferenceinfo.cfm&h=246&w=246&sz=11&tbnid=AET3E3mpE94J:&tbnh=105&tbnw=105&prev=/images%3Fq%3Dgm%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=3

http://images.google.com.sg/imgres?imgurl=http://vw-roechling.de/assets/vw_logo.jpg&imgrefurl=http://vw-roechling.de/&h=300&w=300&sz=21&tbnid=hMT5JavXFDwJ:&tbnh=111&tbnw=111&prev=/images%3Fq%3Dvw%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.british-car-auctions.co.uk/images/Custlogo_Nissan.jpg&imgrefurl=http://www.british-car-auctions.co.uk/main.asp%3Fpage%3D1380&h=208&w=239&sz=26&tbnid=cwBgYEdAd0IJ:&tbnh=90&tbnw=104&prev=/images%3Fq%3Dnissan%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://images.autoanything.com/images/products/sgd/truck_accessories/ford_logo.jpg&imgrefurl=http://www.autoanything.com/shopping_guides/truck_accessories/index.aspx&h=150&w=150&sz=18&tbnid=RflJerr6LZIJ:&tbnh=90&tbnw=90&prev=/images%3Fq%3Dford%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=3

http://images.google.com.sg/imgres?imgurl=http://gankbift.tripod.com/Audi_Logo.jpg&imgrefurl=http://gankbift.tripod.com/&h=380&w=669&sz=75&tbnid=j-6O4nsqEYEJ:&tbnh=77&tbnw=136&prev=/images%3Fq%3Daudi%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.sacc-usa.org/chicago/Photo/volvo_logo.gif&imgrefurl=http://www.sacc-usa.org/chicago/first_page.htm&h=540&w=720&sz=3&tbnid=1nkiXbHFjqoJ:&tbnh=104&tbnw=139&hl=en&prev=/images%3Fq%3Dvolvo%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.mmk.ei.tum.de/admin/lie/bmw_logo.jpg&imgrefurl=http://www.mmk.ei.tum.de/admin/lie/ws_nadia_anno.html&h=380&w=380&sz=36&tbnid=yZ8LFW9fv1cJ:&tbnh=119&tbnw=119&prev=/images%3Fq%3Dbmw%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://www.synlube.com/Logos/MB_Star_logo_BW.jpg&imgrefurl=http://www.synlube.com/syn.htm&h=200&w=200&sz=6&tbnid=TP4bn2gvRAMJ:&tbnh=99&tbnw=99&prev=/images%3Fq%3Dmercedes%2Bbenz%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=2

http://images.google.com.sg/imgres?imgurl=http://mobilechiptune.co.uk/assets/images/citroen_logo.gif&imgrefurl=http://mobilechiptune.co.uk/html/car_database.html&h=217&w=217&sz=12&tbnid=Pqt-tAwgZXgJ:&tbnh=101&tbnw=101&prev=/images%3Fq%3Dcitroen%2Blogo%26hl%3Den%26lr%3D&oi=imagesr&start=3


Auto Industry Tier One Customers

http://www.faurecia.com/

http://www.montaplast.com/index.html

http://www.montaplast.com/index.html

http://www.trw.com/home/main/1,,,00.html

http://www.valeo.com/automotive-supplier/Jahia/pid/2


Amphenol

Electronics and Other Customers

http://www.tycoelectronics.com/default.asp

http://www.metabo.com/

http://www.molex.com/cgi-bin/bv/molex/home_init.jsp?BV_SessionID=@@@@0165825103.1139887142@@@@&BV_EngineID=ccceaddgmkiihhecflgcehedffgdfmk.0

http://www.elster.com/en/index.shtml

http://www.china.philips.com/index.html


Agenda









5.1 Structural Inserts for Body-In-White5.2 Applications under the Hood (UTH)

5.3 Exterior Parts



Targets

Weight / cost saving : currently several metal sheets at cross links

Replaced by Durethan BKV35 parts

Body in white reinforcements : thin pillars to improve visibility

Crash behavior improvement : target 5* EuroNCap

Temperature resistance : activation of "Core Products" foam linking

system during e-coating


Structural inserts – Citroën C4 PicassoParts locations

~256g

~780g

~2300g~1542g

Durethan weight per vehicle ~9.5kg


Structural inserts – Citroën C4 Picasso Safety


Structural inserts – Citroën C4 Picasso Weight saving Source : Citroën


Agenda








5. Technology Examples, Case Studies5.1 Structural Inserts for Body-In-White

5.2 Applications under the Hood (UTH)5.3 Exterior Parts



Cooling Circuit

Beauty CoverAir System

Oil Curcuit

Brackets

Fuel Delivery System

Applications Under The Hood


Under The Hood Technology Life Cycle

Development Introduction Growth Saturation

Brackets

Oil Modules Manifold Modules

Valve Cover

Engine CoverRadiator Tanks

Belt CoverThermostatic Housing

Oil Pan Engine

Oil Pan Gear Box

GIT- Cooling Ducts

Sound Silencer

Cooling Frame

Air Filter Housing

Pulleys

WIT-Cooling Ducts

Air Ducts

Oil Filter

WIT- Cooling Ducts


Reservoir/Pipes Pipes/GIT-WIT Blow mouldingAKV 30 H2.0 DP 2-2224/30 H2.0 AKV 325 H2.0

AKV 30 HR H2.0 DP AKV 30 X HR DP 2-2240/15 H2.0

Durethan® Grades / UnderTheHood Applications

Cooling Circuit

Oil Circuit

Beauty cover

Engine Gearbox Valve coverBKV 35 H2.0 AKV 35 H2.0 AKV 35 H2.0

AKV 35 H2.0 AKV 35 H2.0 SR1 BKV 35 H2.0

DP BKV 60 H2.0 EF DP BKV 60 H2.0 EF

BKV 50 H2.0

CoverBM 29 X H2.0

DP 1100/30 H2.0

DP BM 29 X H2.0 EF 900116

DP1441/40 H2.0 EF 900116


Manifold Charge Air Tube Air Cleaner | TubeBKV 30 H2.0 BKV 30 HTS BKV 30 H2.0

BKV 35 H2.0 AKV 35 HR H2.0 BKV 15 H2.0

BKV 330 H2.0 AKV 30 H2.0 DP 2-2140/15Z H2.0

BKV 30 H2.0 EF AKV 325 H2.0

Durethan® Grades / UnderTheHood Applications

Fuel DeliverySystem

Air System

Brackets

Fuel Rail Active Charcoal FilterAKV 30 H2.0 BKV30 H2.0

AKV 35 H2.0

Bracket Transport Bracket (anti-static)BKV 30 H2.0 DP BCF 30 X H2.0

BKV 35 H2.0

BKV 50 H2.0

DP BKV 60 H2.0 EF


Agenda










5.3 Exterior Parts5.4 Structural Plastic-Metal-Hybrid Parts


Front Panel (Radiator Grille) DC Truck Actros

Application Examples

LANXESS Introduction, Overview 11th Dec 2007 Page 45 Motohiko Kato, Thomas Babl


Headlamp Bezels in Durethan and Pocan

Citroen C3&C3

Fiat Ducato

Fiat Croma

Peugot 307 Break



Door Handles in Durethan for Jaguar, Ford, VW, Mercedes Benz, GM, etc.


Agenda










5.3 Exterior Parts



Audi A6 – 1998 Audi A4 – 2000 Audi A2 – 2000 Audi A8 – 2002 Audi A6 – 2004 Audi A4 – 2004 Ford Focus – 1998 Ford Fiesta – 2001

Ford Fusion – 2002 Ford Focus Cmax – 2003 Ford Focus – 2004 Ford Freestyle - 2004 BMW X3 – 2003 BMW 1er – 2004 BMW 3er – 2005 Mercedes Benz Vito – 2003

Mercedes Benz A – 2004 Chrysler 300C – 2004 VW Polo – 2001 VW Phaeton – 2002 Nissan Altima – 2001 Nissan Maxima – 2002 Nissan Quest – 2003 Nissan Titan – 2004

Nissan Armada – 2004 Nissan Infinity – 2004 Seat Ibiza – 2001 Renault Megane – 2002 Mazda Demio – 2002 Hyundai Getz – 2002 Hyundai Sonata – 2004 Hyundai Tucson – 2004

Hybrid-Frontends in Mass ProductionCars with Durethan Hybrid Frontends


plastic-metal hybrid is well known and established.

over 55 cars are using Hybrid Technology, over 25 Mio. Hybrid parts manufactured.

Ford Galaxy – 2006 Ford S-Max – 2006 Audi TT – 2006 Hyundai Avant– 2006 Hyundai Veracruz– 2006 Hyundai Santa Fe – 2006 Kia Carens – 2006 Kia Lotze – 2006

Kia Spectra – 2003 Kia Picanto – 2004 Kia Sportage – 2004 DC B-Klasse – 2005 Dodge Charger – 2005 Ford five hundred – 2004 Ford Freestyle – 2004 Mercury Montego –2004

Hybrid-Frontends in Mass ProductionCars with Durethan Hybrid Frontends


Hybrid Technology PrinciplePlastic Keeps Metal in Shape

geometry collapses at much higher forcesimproved utilization of sheet metal structure properties

low forces keep

structure in shape

light weight design(thin wall thickness)

tends to buckling

簡報者

簡報註解

This slide shows you the principle of hybrid technology. Light weight parts made of steel have to be thin walled. Unfortunately thin walled parts tend to buckling – as you can see when I twist or bend this metal sheet. But we know from statics that we can keep the structure in shape with very low forces. This is one of the tasks of the plastic that we bring into the structure by injection moulding. Due to this the geometry collapses later and the properties of the steel are better utilized. In the upper area of the slide you see some typical hybrid geometry elements, which are: injection moulded buttons (comparable to rivets) ribs over moulded areas. Process: First the steel sheet has to be processed. Then the steel sheet is put into the mould and over moulded with plastic. One of the additional advantages here is the integration of functions. This is a typical advantage of the injection moulding process.


• design freedom• low density• excellent performance

under dynamic loading

Metal• high strength and

stiffness in a wide temperature range

• ductile crack behaviour

• low CLTE• good deep drawing

behaviour

The Best from Two Worlds

Hybrid

• reduced tendency to buckling ofthin wall metal structures

• high energy absorption• high temperature resistance

(e-coating capability)• low part weight by thin walls• high precision in

production and use• high integration of

functional elements

Polyamid 6 GF

Hybrid Technology Principle

簡報者

簡報註解

So Hybrid Technology for us means that we use the best from two worlds: Metal and Polyamide 6 GF (Durethan B), or let me say plastics. The polyamide from the plastics point of view offers design freedom good impact strength high dynamic capacity and chemical resistance The steel gives us the well known properties like high strength and stiffness etc. Hybrid technology (under Bayer patent) now combines the properties for the realization of highly integrated structural parts. These parts have a reduced tendency to buckling and show a high energy absorption.


Positive joint with undercut

Connection of Plastic and MetalHybrid Technology Principle


Life Cycle of Hybrid Applicationsm

arke

t pen

etra

tion

Development Introduction Growth Saturation

body in white parts

PA Frontend

Side Door

Rear Back Seat

Cross Car Beam

Roof Frame

Antenna Module

Door Strip

Pedal Box

Brake Pedal

Body in White Parts



Deflection Behavior in 3-Point Bending TestComponent Properties

Forc

e F

[kN

]

4,0

3,0

2,5

2,0

3,5

1,5

0,5

0

Deflection f [mm]80 2 4 6 10 12 14 16 18 20

50

Metal/plastic Hybrid profile

Closed metal profile

Open metal profile

340

f

F

40


Deflection Behavior CompressionFo

rce

F [

kN]

25

20

15

10

5

0

Deflection f [mm]2,40 0,8 1,6 3,2 4 4,8

340

50

40



Open metal profile

Component Properties


Mom

ent M

[N

m]

40

25

20

15

30

10

5

0

Rotation Angle ϕ [°]80 2 4 6 10 12 14 16

340

35

50

40



Open metal profile

Deflection Behavior TorsionComponent Properties


Design FeaturesSheet Metal Profile and Plastic Rib Structure


Overmolding at sheet metal flange

Intersection point in sheet metal profile

Design FeaturesPositive Joint with Undercut


Design FeaturesConnecting additional Full-Plastic Structures


Bearing

Foot plate

Fixation of booster rod

Design FeaturesIntegration of Functions

Fixation forbrake light switch


Open mold Demold finished partPositionsheet metal insert

Economical manufacturing through combination of metal stamping and injection molding process mass production approved

Manufacturing of Hybrid Parts


Mold closing(close core pullers)LockingPosition injection unitInjectionHoldingCoolingMeteringPull back injection unitDe-locking(open core pullers)Mold openingDemolding and handling

Cycle Time

Zykluszeit44

14

36

1715

41

44

12

10 20 30 40 50 60 70 0 s

58

Cycle Time of Frontend Carriers - Example

Manufacturing of Hybrid Parts


Türen und Heckklappen

Knotenelemente

Durethan BKV 30 H2.0

Roof Frame Audi A6 – Body ShopOnline Painting Application Example


Standard GF

• Durethan BKV 15

• Durethan BKV 30

• Durethan BKV 115

• Durethan BKV 130

High-filled

• Durethan BKV 50

• Durethan BKV 60

Easy Flow

• Durethan BKV 30 EF

Suitable Thermoplastic Materials

Materials for Hybrid Applications

EXtreme Flow

• Durethan BKV 30 XF

In principle all semicrystalline thermoplastic materials, especially GF- gradesWall thickness between 1.2 and 6 mm (in exceptional cases up to > 6mm)


• Higher Integration• Cost reduction (-20 %) • Weight reduction (-40 %)• High dimensional accuracy• Lower investment costs (-50 %)

Durethan® BKV 30 (PA6 GF30)

Advantages compared to previous solution(Standard metal structure)

Ford Focus Grille Opening Reinforcement Durethan BKV 30 H2.0



Part: Front End Module Carrier Audi A2Material: Durethan® BKV15 H2.0 (PA6 GF15)/ SheetmetalInnovation: Hybridstructure in combination with In Mould Assembly

Application ExamplesAudi A2 Frontend Module CarrierDurethan BKV 15 H2.0


Bumper beamAirduct unit Outside temperature sensor

Head lampcondensor

Oil dip stick

Horn

Inlet connection piece

Front flaps lock x2 (not illustrated)

Front hood sealing gasket

Head reinforcement(not illustrated)

Audi A2 Frontend Module CarrierDurethan BKV 15 H2.0


Water reservoir

Fan

Inter cooler

Oil reservoir

Air filter

Fresh air inletRadiator

Protective Shield

Water drain

Condensor bracket

Pressure hose



Volvo XC90 „Antenna Tuner Module“

photo: VOLVO


All Antennas in one Module


Hybrid Front Panel DC Truck ActrosApplication Examples


• Weight reduction ~30%• Cost reduction ~10-30%• Integration of fixing elements• Ductule failure mode• Certainly suitable for small and middle

size cars, feasibility for bigger cars and trucks need to be tested case by case

• Optimal solution in combinations with pedal box

Load[kg]

Deflection[mm]0 10 20 30 40 50

80160240320

Hybrid Brake PedalApplication Examples


Producer: DAFMaterial: Durethan® DP BKV60 H2.0 EF (PA6 GF60 Easy Flow)Major Advantages: High stiffness

Hybrid Break Pedal, Mass Production DAF




Fiat Ducato Hybrid Break PedalDurethan BKV 30 H2.0Mass production since 06/2006


Strength and Limitations of Hybrid Technology

• Complex structures providing high mechanical performance possible

• Low weight

• High stiffness

• Good dimensional accuracy

• Excellent dimensional stability

• Corrosion resistance

• Low number of additional fixing elements

• Easy integration of functional elements

• Mass production approved manufacturing processes

• Reduced part costs

• Lower investment costs compared to full steel solution

• No post molding treatment required

• Easy to recycle

• Achieving cost advantages normally requirehigh-volume production

• Involvement of two different processes, which needto be fine-tuned with respect to each other

• Higher investment costs compared to full plasticssolution

Advantages Limitations


1. Project Acquisition • Benchmarking & Reviewing the previous projects • Initial Concept & Assessment

Based on existing model Cost estimation & feasibilityDecision for further progressSelecting target model & setting up requirementsSetting out targets – cost/weight/performance target

2. Feasibility study step/Proto-Development (~ 14 months)

• Concept Design (~ 3 months)Basic structure & Integration conceptLinear CAE analysis

• Detail Design (~ 4 month)Part designMechanical CAE analysisRheological analysis

• Tooling & Molding trial (~ 4 months)• Verification (~ 3 months)

Assembly, Part testing & Evaluation

Project Steps


Thank you for your attention.

Thomas BablPhone: +852 3526 [email protected]

mailto:[email protected]

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