Plastics News Europe - June 2018 - 10

AUTOMOTIVE: VDI CONGRESS

➡ Continued from page 9
Fraunhofer ICT institute for chemical
technology and Karlsruhe Institute of
Technology (KIT).
While the project focussed on a
90kW (123hp) 260Nm torque motor
for electric drive vehicles, Arburg may
also use ProLemo drives in moulding
machines. Walther said one has already been running at Arburg in a
size 400 injection unit since January
2018. He said it is still too early to
make a firm statement on costs, as
the work has not yet been applied on
a sufficiently large scale.

Metal/plastic hybrids
On the topic of hybrid lightweight
construction, Joachim Melzig, predevelopment manager at BMW in Land-

Lanxess has developed a new hollow profile hybrid
process

shut, confirmed to PNE that, despite
the launch in 2015 of its "Carbon
Core" chassis construction technique, there will be some reduction
of carbon fibre content in future
BMW 7-series models. This is due to
cost and assembly issues. Melzig
stressed here that, "reducing assembly costs is the only reason to use
hybrid metal/plastic parts, as they
enable affordable lightweight construction together with functional integration".
Production of the BMW i3 with its
CFRP passenger cell in Leipzig is "special", Melzig said, adding that CFRP
use must otherwise fit in with existing
assembly lines. Although lower overall car weight with plastics reduces
axle loads, the effect on electric drive
car range is much lower than when
paying attention to more efficient,
lighter weight batteries, Melzig observed.
Although not addressed by
Melzig, this has come to light separately in recent tests by the CAR institute in Duisburg that showed increasing car weight with several bags of
pebbles actually increased the range
- due to more breaking energy recuperation with a heavier car.
Lanxess showed, as at the 2018
IKV plastics colloquium, a new hybrid

10

approach in which aluminium or steel
tubes are overmoulded with GF60PA6 (Durethan BKV 60EF) and Tepex
GF-PA organic sheet. Strengthening
elements selectively applied within
round or rectangular tubes prevent
collapse under 700bar injection
moulding pressure.
The resulting hollow profile hybrid
(HPH) benefits from higher strength
and torsional stiffness than with sheet
metal based hybrids, illustrated with a
demonstrator fitted with Danny Mascaskill Lizard Skin Lock-on bicycle
handlebar soft grips.
HPH is similar to the established
simultaneous internal high-pressure
hydroforming and injection overmoulding process used by Daimler
and ElringKlinger for instrument panel (IP) and frontend carriers. Lanxess
also sees potential for the HPH technique in such carriers, but with lower
plant investment.
Lanxess lightweight projects manager Lukas Schröer noted that HPH
could also be used with different
types of extruded metal profile or cast
metal inserts. "Hollow fibre reinforced plastic profile inserts can also
be used for serial production of even
lighter structural parts", Lanxess hybrid technology specialist Boris Koch
suggested.

JUNE 2018


http://www.schobertechnologies.de

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