12 Nov 2019 / Innovation

Carbody chooses brand new Technyl® Max to develop all-polymer brake pedal

  • Innovative high rigidity Technyl® range for lightening semi-structural parts
  • Exceptional resistance to fatigue and high frequency vibrations of electric vehicles
  • Used in the first brake pedal without a metal core

Lyon, France, Oct. 16, 2019 – Solvay’ new and advanced Technyl® Max polyamide 6.6 (PA6.6) technology was chosen by Carbody, expert in safety and sealing solutions for the automotive industry, to develop its all-plastic brake pedal. Designated ‘Skeleton’, the revolutionary pedal concept made in Technyl® Max replaces conventional steel design with a lightweight hybrid structure.

Automotive OEMs and Tiers are increasingly looking for high rigidity materials to substitute a range of metal components for the lightweighting of new energy vehicles,” comments Gérald Durski, Marketing Director for Solvay’s Performance Polyamides. “It was a great opportunity for us to co-design Skeleton in close partnership with Carbody, demonstrating the performance of our brand new highly-filled Technyl® Max”.

Skeleton features a rod-shaped composite structure which is over-molded with 60 percent glass-filled new Technyl® Max technology. This provides the Skeleton brake pedal superior fracture resistance under loads up to 3.000 N and even maintain its operational safety beyond that limit. In regards, the average force applied in case of emergency brake is around 500 N.

“The strength of this new Technyl® Max was instrumental in maximizing lightweighting for our unique pedal concept,” explains Loïc Lefebvre, R&D Expert at Carbody. “We have been relying on Technyl® team’s expertise in metal replacement for many years; their upgraded HUB advanced service platform is a key differentiation lever to optimize design and performance for demanding safety parts.

In addition to car pedal systems, the new Technyl® Max targets semi-structural components such as transmission and motor mount cross beams, air shutter grills and seat structures. Its low density offers significant weight savings over typical die-casting metals at comparable tensile strength. This is of importance for applications in EVs which require even greater rigidity and fatigue resistance due to higher frequencies.

This co-development is backed by the Technyl Force extensive experience in metal replacement. Unveiled at K 2019, HUB by Technyl® is a unique platform – which includes MMI® Technyl® Design1 predictive simulation – that connects together advanced services to provide customer innovation with enhanced capabilities and synergies for eco-design agility and cost optimization.

® Technyl, HUB by Technyl and MMI® Technyl® Design are registered trademarks of Solvay.
1 MMI® Technyl® Design is an advanced service powered by Digimat® from e-Xstream, an MSC Software Company.

 

Carbody brake pedal made with Technyl® MAX.