MOSCOW (MRC) -- Lanxess has achieved a process innovation in the production of continuous fiber-reinforced thermoplastic Tepex composites, as per the company's press release.
The subsidiary company Bond-Laminates, which manufactures these composites, is now able to continuously series-produce large semi-finished composite products in which the continuous fiber layers can be oriented at almost any conceivable angle. Until now, the continuous fibers in Tepex could only be lined up in the direction of production or perpendicular to it (0 degrees or 90 degrees). This process innovation means the designer can use the differently oriented composite continuous fibers to help him react more specifically to the force transmission in the target component. Even quasi-isotropic constructions can now be fashioned using Tepex.
"This means Tepex can be used to design lighter-weight composite components that are tailored even more specifically to the load in question. So the new-generation Tepex strengthens our position as a leading supplier of thermoplastic high-performance composites for lightweight design," says Dr. Dirk Bonefeld, head of Research and Development at Bond-Laminates.
These multiaxial Tepex semi-finished products are fully impregnated and consolidated. Despite being formable to quite extreme angles, their impregnation means the fibers are unlikely to slip. As in the past, Bond-Laminates will consult closely with the customer regarding cutting the semi-finished products into pre-contoured profiles for forming and overmolding or compressing. Special nesting programs help keep wastage to a minimum in almost all cases.
"Thus the processor receives a fully constructed, made-to-measure composite material that can be shaped into highly load-resistant, complex components in very short cycle times without generating wastage," says Bonefeld.
Their high-quality mechanical set of properties, which can be tailored to meet specific requirements, makes multiaxial Tepex semi-finished products the perfect material for manufacturing high-strength structural components and semi-structural components for automobiles in particular.
"For example, we are currently working on front end carriers, pedal and seating components, carriers for electrical and electronic modules, engine compartment guard plates, airbag housings and components used in underbody protection. We are also looking at components that require custom construction for meeting a combination of torsional and flexural load requirements," Bonefeld adds.
As MRC said before, Lanxess has successfully concluded the pilot phase for a highly efficient production process for butyl rubber. In the past seven years, Lanxess worked on a fundamentally new technology for a more sustainable production. An important step in this process was the testing of the new technology in two pilot plants at its production site in Zwijndrecht/Belgium since spring 2012.
Lanxess is a leading specialty chemicals company with sales of EUR 8.3 billion in 2013 and roughly 17,300 employees in 31 countries. The company is currently represented at 52 production sites worldwide. The core business of Lanxess is the development, manufacturing and marketing of plastics, rubber, intermediates and specialty chemicals.