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Skywalk manufactures a paraglider reclining harness with a high-performance, continuous fiber-reinforced and polypropylene-based composite.
The composite material Tepex dynalite from Lanxess subsidiary Bond-Laminates is performing even in extreme sports applications. This material is a high-performance, continuous fiber-reinforced and polypropylene-based composite. It is used in the Range X-Alps paraglider reclining harness manufactured by skywalk GmbH & Co. KG during a competition challenging the athletes to cross the Alps by paraglider and on foot. The harness’s footboard is made of a sandwich composite just one centimeter thick, comprising thin Tepex facings measuring just 0.5 millimeters and a polypropylene honeycomb core from EconCore N.V.
Just as rigid, but lighter than sheet steel or aluminumTo control a paraglider, the pilot must shift his body weight, while maintaining muscle tension. This is achieved by pushing the feet against the harness’s footboard. In extreme situations, such as sudden turning maneuvers when approaching a steep rock face, very high forces are applied to the footboard, comparable to fully depressing the brake pedal in a car to avoid an accident.
Twenty percent lighterThe tough Alpine course requires pilots to have a high level of physical fitness, but also the lightest possible equipment. The sheets are 20 percent lighter than earlier versions made from a carbon fiber-reinforced epoxy resin. The harness therefore weighs just slightly more than one kilogram. Another advantage is the low costs: the new component costs 25 percent less than the epoxy system.
Further applications in automotive engineeringLanxess also sees major opportunities for sandwich composites of this kind in lightweight automotive construction, particularly in larger parts requiring rigidity, such as trunk floors, fuel tank covers, range extender housings, structural battery housings and seat components. Fuel tank covers, which form part of the trunk space, are another conceivable application. They would be significantly lighter than their counterparts made of sheet steel or aluminum. Furthermore, functions such as slots, guides or mounts can be integrally molded in the covers in a single processing step to further cut costs.
Automated production of honeycomb compositesEconCore has developed a fully automated production system called ThermHex to manufacture honeycomb sandwich panels with Tepex composite skins. “Thanks to this technology, we can produce these ultra-strong sandwich structures cost-efficiently and in high, reproducible quality,” says Tomasz Czarnecki, technology manager of the company, which is based in Leuven, Belgium, but also maintains a production site in Halle/Saale Germany, through its ThermHex Waben GmbH subsidiary.
Lanxess provides extensive customer support in the development of components made of sandwich composites with Tepex facings. These services are part of its HiAnt customer service package. The HiAnt brand encompasses all of Lanxess' engineering expertise concentrated in its high performance materials business unit. This know-how extends to thermoplastic materials, composite technologies, component testing, simulation methods and processing. Paraglider manufacturer skywalk likewise benefits from HiAnt.
More information: www.lanxess.com - www.skywalk.info - www.econcore.com
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