Bayer develops novel production concept for automotives

The prototype on display at K 2013 is a perfect example of the great design freedom offered by plastics from Bayer MaterialScience. To promote the realistic use of the concept part in a vehicle, the company also developed an intelligent solution for mounting it to the rear of the vehicle.

“Nature once again proved to be the best master builder in this case,” says Grosser. The task was to devise a robust and lasting connection between the hinge and the lightweight structure of the trunk lid. “To find a solution, we studied how trees are anchored to the forest floor,” Grosser explains. “A network of roots lends even tall and heavy trees a secure hold in soil that frequently is soft.”

For a realistic solution, the Bayer researchers optimized the look of the hinge mount using computer-aided engineering (CAE). The resulting plastic structure looks remarkably like the roots of a tree in the ground. Tests confirm that the hinge mount can be attached easily and holds very firmly in the lightweight foam core.

Quality sandwich components for premium products

“We passed a milestone in the efficient production of sandwich components with this material-based design,” says Dr. Olaf Zöllner, summarizing previous developments. However, the Head of Application Technology for polycarbonate sees this body part as just one example of the numerous possibilities of the new technology.

“Such lightweight and stiff composites made from polycarbonate blends are excellently suited to the fabrication of ultrabooks and other high-tech products, for example,” Olaf Zöllner says. There are also promising prospects for furniture manufacturing and many other applications. “The auto industry often leads the way in pioneering technical developments, but we are also looking forward to talks with customers and partners in other industries.”

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