Damme/Düsseldorf. Plastic brake pedal of the BOGE Rubber & Plastics Group, a global supplier of vibration technology and plastic solutions to the automotive industry, was awarded first place in the Automotive Award in the category "Body Interior" by the Society of Plastics Engineers (SPE) in Düsseldorf on Monday (17 October). The safety component is installed in the Porsche Panamera and Bentley Continental. The panel of experts who formed the jury particularly appreciated the fact that the plastic brake weighs about less than half the weight of a comparable steel structure
The entire development of the plastic brake pedal – right from component part and tool design through the all-up process development to component part testing - was in the hands of BOGE Rubber & Plastics. In the structural design of the component parts, BOGE was supported by Bond-Laminates, a subsidiary of LANXESS AG.
The plastic pedals can be manufactured in high quantities at costs comparable to conventional steel brakes, due to the high functional integration of the plastic version and the completely automated production. "In addition, the pedal can be produced in an economical one-shot process in a large-scale injection molding cycle," stresses Burkhard Tiemann, head of the product line Plastics at BOGE Rubber & Plastics.
The brake pedal was designed in two versions, one each for left and right-hand driven vehicles. The fact that drivers brake with their left or right foot had also to be taken into account in the design stage. For this purpose, the load path was optimized according to the different torsional directions. The component part is produced by hybrid molding in a one-shot process in short cycle times suitable for large series.
The brake pedal is able to fulfill even high load requirements thanks to a multi-axial fiber layer structure in the Tepex insert. These continuous fiber reinforced thermoplastic composites are developed and manufactured by Bond-Laminates GmbH. The top layers ensure excellent tensile and bending strength and the inner layers ensure a high torsional-load bearing capacity of the brake pedal. "With this laminate, it was possible to meet the very high technical requirements for the mechanical performance of the safety component while at the same time utilizing the optimum of lightweight construction potential," Tiemann states. He adds that intensive work is already being done to climb the next rung on the evolutionary ladder of fiber composite construction. It is planned to introduce the next generation in 2019 ready for series production.
The SPE Awards are among the most prestigious awards for innovations in the automotive industry and its suppliers. The award has been assigned every one and a half year since 1992. This year's awards were presented in Düsseldorf on 17 October.
BOGE Rubber & Plastics, is a top player among the leading worldwide automotive suppliers in the field of rubber-metal and plastics technology and employs about 4,000 employees generating an annual consolidated turnover of approx. million 740 Euro. The company headquartered in Damme (Germany) is represented internationally at ten locations - Damme, Simmern, Bonn (Germany), Trnava (Slovakia), Fontenay (France), Sorocaba (Brazil), Dingley (Australia), Hebron (USA), Qingpu, Zhuzhou (both China) - in seven countries. BOGE Rubber & Plastics is a division of the Chinese Zhuzhou Times New Material Technology Co., Ltd. (TMT). TMT is a subsidiary of China Railway Rolling Stock Corporation Ltd. (CRRC), a Group which employs about 180,000 people. More information at www.boge-rubber-plastics.com.
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Photo: A plastic brake pedal of the BOGE Rubber & Plastics Group, which is installed in the Porsche Panamera and Bentley Continental, was recognized by the Society of Plastics Engineers (SPE) with a first-place ranking in the category “Body Interior”.