LANXESS is expanding the range of applications for extrusion blow molding: continuous fiber-reinforced thermoplastic composites under the Tepex brand can also be integrated into the production process. In a feasibility study, experts from the specialty chemicals company demonstrated that parts made of polyamide 6 can be manufactured using blow molding technology while receiving local reinforcement by Tepex where heavy loads are carried out. The studies were carried out on a state-of-the-art, closest to production blow molding machine in the technical center of Dormagen's High Performance Materials Business unit (HPE). Arthur Rieb, blow molding specialist in the High Performance Materials Business unit, explains: ""These components have excellent adhesion, which makes it possible to take advantage of Tepex's extremely high strength and stiffness.""

this method can be used for local improve the mechanical performance of blow molding parts, such as due to the impact load or high pressure and high mechanical stress area. ""In addition, it is suitable for the manufacture of blow molded structural parts, such as hollow profiles for body reinforcement. The widespread use of Tepex could be a key factor in reducing weight and material use, as the basic wall thickness of the component can be reduced. Based solely on thermoplastic systems, hollow parts are easy to recycle and therefore easier to establish closed loop material cycles. The

Blow molding step determines the cycle time

When making this hollow part, the machine first extruded the tubular form blank while the heated and plasticized Tepex plug-in was placed into the blow molding tool. The billet is then inflated in the tool, thus also forming the Tepex profile. This will give the part a preset shape and local Tepex reinforcement. ""Tepex molding is integrated into the blow molding process. As a result, we have found a one-step molding process with a short, cost-effective blow molding cycle."" Rieb adds.

Simplified process

Previously, such manufactured parts included the subsequent soldering of a 2D or 3D Tepex plug-in to a blow molded hollow part. In the first case, there were two stages to the process, while in the second case, with the previous Tepex molding, there were three stages. Tilmann Sontag, lightweight design specialist at Tepex Automotive Group in the High Performance Materials business unit, says: ""Our process therefore makes production much simpler. In addition, the fabric reinforcement material makes the plasticized Tepex material easier to handle than tape that is unidirectionally reinforced with continuous fibers. This enables a stable and safe production process.""

full consolidation material bonding

Tepex in continuous fiber completely with plastic dipping. As a result, the pressure in the blow molding process is sufficient to consolidate the material, so no air pockets form. ""So we get a material that has excellent adhesive properties between blow molding and Tepex. Even a low blow pressure is enough to make the Tepex form key 3D geometry, such as a small radius hemisphere."" ""Sontag says.

Multiple Blowable polyamides

The Performance Materials business unit has developed a variety of products, both with and without glass fiber reinforced materials, all based on the high-viscosity compounds of polyamides 6 and 66. These materials can also be used in new process/material combinations. The range includes very soft, impact-resistant product variants, such as the unreinforced polyamide 6 compounds Durethan BC700HTS DUSXBL and Durethan BC550Z DUSXBL. This material is ideal for use in TepeX-reinforced storage tanks or other hollow parts. They also require high impact resistance and flexibility in applications. In contrast, fiberglass reinforced product types tend to be the material of choice for lightweight structural components.

With Tepex, the process is also available in a variety of product types: for example, material variants reinforced with continuous fiber fabrics or laminates made of glass, aramidon or carbon fiber. The matrix of the composite material can also vary. For example, in addition to polyamide 6 or 66, it can be composed of polyolefins such as polypropylene or polyethylene.

HiAnt – Comprehensive customer service

The LANXESS Performance Materials Business Unit combines its expertise in materials, applications, process and technology development under the HiAnt brand, thus enabling it to support customers at all stages of component development. The service covers all processes from conceptual design, material optimization and calculation of component characteristics through simulation tools to handling, component testing and the start of mass production.