Plastics News - Show Daily - October 18, 2023 - 12

12 * Plastics News, October 18, 2023
FAKUMA SHOW DAILY
A new company, Envalior, brings its new HPH technology to Fakuma
By David Vink
Plastics News Correspondent
Envalior, the Cologne, Germany-based
company created in
April through the combination
of DSM and Lanxess engineering
thermoplastics business, comes
to its fi rst Fakuma with a worldwide-fi
rst commercial application
of its HPH hollow profi le hybrid
technology.
It involves a Dongfang Jiangsu
light commercial vehicle front end
beam that saved 20-30 percent
weight substituting welded metal.
HPH involves overmolding thermoplastic
functional
elements
over hollow metal profi les. The
material of choice earlier was Durethan
BKV60 H2.0 EF, a 60 percent
glass-fi ber-reinforced nylon 6,
which has easy fl ow yet strength
through shear-thinning H.20 technology.
The Dongfang Jiangsu part
now uses an even higher modulus
BKV60 H2.0XF grade.
Lanxess has talked about and
shown HPH demonstration parts
since 2018. It had been considered
essential to use internal
profi le supports at overmolded
points to prevent profi le collapse
under high mold cavity melt
pressure of more than 700 bar, as
described by Martin Wanders of
Lanxess at the 2018 IKV plastics
technology colloquium.
That has changed, Envalior
lightweight
construction manager
Matthias Theunissen exENVALIOR
DEUTSCHLAND
GMBH
Hall B4, Booth 4302
plained at the VDI PIAE plastics
in automotive engineering congress
in June 2023.
Theunissen said development
started in November 2021. Soft
tooling and fi rst trial parts were
available in the second quarter
of 2022 and serial production
started in December 2022. He
showed how a 2.7-millimeter
wall thickness aluminum tube is
exposed to 400 bar cavity pressure
for several seconds, before
falling to 350 bar after 10 seconds
and 100 bar after 25 seconds process
time.
But a ribbed aluminum tube of
unspecifi ed lower wall thickness
can be overmolded at initial 300
bar cavity pressure, falling to
around 30 bar after 25 seconds.
Steel tubes with 1 millimeter wall
thickness can be overmolded at
250 bar, falling to 50 bar after
20 seconds. But if elements are
welded to the steel tube, it can
be overmolded with around 180
bar cavity pressure.
The key to avoiding internal
supports is selection of a suffi cient
wall thickness for the type of metal,
use of ribbing, external crimped
or welded-on elements and precise
ElringKlinger
cockpit
crossbeam
carrier.
Envalior photos
America and South Africa.
In a September 2023 fi nancial
analysts presentation, ElringKlinger
referred to supply of
cockpit crossbeams in 2023 to a
further global automotive OEM,
worth " low double-digit millions
of euros per annum. "
PMH is an HFH " hydroformed hybrid "
process, in which closed hollow
metal profi les are overmolded
by Durethan BKV60 H2.0EF.
Profi le collapse is prevented
by fl uid inside the profi les at
1,000 bar pressure to hold the
metal against the mold during
overmolding.
That thousands of PMH cockpit
Early Lanxess
HPH hollow
hybrid profi le
demonstrator.
process control to ensure profi les
withstand cavity pressure.
HPH investment cost is lower
than alternative PMH polymer-metal
hybrid
technology
used since 2014 by Dettingen
an der Erms, Germany-based ElringKlinger
AG, fi rst in Suzhou,
China. HPH was developed by
and has been used even earlier
by Mercedes-Benz for front end
crossbeams and was licensed later
to ElringKlinger, which spread
applications to China, North
ASIA
13-14 November 2024
Marina Bay Sands, Singapore
2024 will see the launch of the Plastics Recycling Show Asia.
PRS Asia will be held in Singapore in November 2024.
www.prseventasia.com
Interested in booking a stand? Contact mabarber@crain.com
Organised by
In association with
MIDDLE EAST
& AFRICA
10-12 September 2024 Dubai
PRS Asia 2024 half page for Fakuma show daily.indd 1
05/10/2023 07:42
Supported by
crossbeams and front-end carriers
have been produced alone for
the Mercedes-Benz C-Class car
indicates signifi cant future potential
for the competing Envalior
HPH process, now that it no
longer needs internal profi le support.
In any event, it is a win-win
situation for Envalior, as it supplies
nylon 6 for both processes.
Envalior has not revealed process
details for Dongfang Jiangsu
parts, but the PMH process at Mercedes
uses a Vestamelt X1333-P1
adhesion promoter from Marl,
Germany-based
Evonik
Operations
GmbH. ElringKlinger molds
PMH parts on a
2,700-tonnes
Engel injection press on a tool
weighing 32 tonnes from ElringKlinger
mold making subsidiary
Lenningen, Germany-based
Hummel-Formen GmbH.
http://www.prseventasia.com

Plastics News - Show Daily - October 18, 2023

Table of Contents for the Digital Edition of Plastics News - Show Daily - October 18, 2023

Plastics News - Show Daily - October 18, 2023 - 1
Plastics News - Show Daily - October 18, 2023 - 2
Plastics News - Show Daily - October 18, 2023 - 3
Plastics News - Show Daily - October 18, 2023 - 4
Plastics News - Show Daily - October 18, 2023 - 5
Plastics News - Show Daily - October 18, 2023 - 6
Plastics News - Show Daily - October 18, 2023 - 7
Plastics News - Show Daily - October 18, 2023 - 8
Plastics News - Show Daily - October 18, 2023 - 9
Plastics News - Show Daily - October 18, 2023 - 10
Plastics News - Show Daily - October 18, 2023 - 11
Plastics News - Show Daily - October 18, 2023 - 12
Plastics News - Show Daily - October 18, 2023 - 13
Plastics News - Show Daily - October 18, 2023 - 14
Plastics News - Show Daily - October 18, 2023 - 15
Plastics News - Show Daily - October 18, 2023 - 16
Plastics News - Show Daily - October 18, 2023 - 17
Plastics News - Show Daily - October 18, 2023 - 18
Plastics News - Show Daily - October 18, 2023 - 19
Plastics News - Show Daily - October 18, 2023 - 20
Plastics News - Show Daily - October 18, 2023 - 21
Plastics News - Show Daily - October 18, 2023 - 22
Plastics News - Show Daily - October 18, 2023 - 23
Plastics News - Show Daily - October 18, 2023 - 24
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