Will you trust the "first ever" plastic brake pedal on Porsche Taycan

Aaron Smith's image
Aaron Smith 

Automotive Journalist

April 22, 2020  at 7:33 PM

Recently, around April 7, 2020, the company released information about their first-ever fully plastic brake pedal that is going to come in the upcoming Taycan electric sports sedan. It is an important safety feature of the vehicle made by BOGE Elastmetall GmbH, which provides technologies of vibration and plastic applications catering to the automotive industry across the globe. The technology is developed with the Lanxess High-Performance Materials (HPM) cooperation.

Two years ago, Porsche showcased its interest in new technologies and materials in an article called “Materials of the Future.” The report centered on critical and unnoticeable equipment and techniques such as 3-D hybrid A-pillar, brake pedal, stainless steel powder, rotor shaft, 911 GT2 RS side window, and gorilla glass.

Recently, around April 7, 2020, the company released information about their first-ever fully plastic brake pedal that is going to come in the upcoming Taycan electric sports sedan. It is an important safety feature of the vehicle made by BOGE Elastmetall GmbH, which provides technologies of vibration and plastic applications catering to the automotive industry across the globe. The technology is developed with the Lanxess High-Performance Materials (HPM) cooperation.

The plastic pedal’s robust mechanism and low weight are because the design is thermoplastic. The structure consists of Tepex Dynalite insert, which is a thermoplastic composite made from continuous-fiber-reinforcement. Tepex Dynalite inserts assisted with numerous tapes.

Porsche Gmbh Composite technology

Dr. Klaus Vonberg, a lightweight design expert at HPM Tepex Automotive Group, also shared his views with a few sources. According to him, the new plastic pedal’s composite structure is half percent lighter than the previously used steel structures. He also informed the resources that the structured pedal meets the load needs of the vehicle due to the qualities mentioned above, which includes Tepex Dynalite insert along with numerous reinforced tapes.

Additionally, he stated that due to the extensive automation properties, the pedal is a safety-critical and geometrically complex part that is capable of both efficient and large scale manufacturing.
Moreover, the Tepex Dynalite makes use of the thermoplastic matrix, which typically involves the reinforcement of continuous glass-fiber fabric layers. Furthermore, the upcoming electric Taycan sports trim makes use of polyamide six matrix composite structure.

The matrix consists of fiber layers which are unidirectional laid out in 45° angles and placed on two covering layers. The tensile and bending strength of the part comes from the inner layers. The thin, unidirectional plastic strips, also called tapes, come along with robust continuous fiber systems and are incorporated into the thermoplastic matrix. The bottom side of the pedal is reinforced with glass-fiber rovings and numerous tapes.

2020 Porsche Taycan plastic brake pedal

Furthermore, the tapes are welded on the Tepex insert with the assistance of a laser because the insert comprises of plastic matrices that are mutually compatible. As a result, fiber layers precisely follow load paths and accommodate the exact load requirements of the component. The insert cover layers come with 45° fiber layers along with tapes on the top end. Therefore, this ensures the pedal’s high torsional strength.

According to sources, Dr. Daniel Häffelin, who works at the Innovation Center, BOGE Elastmetall, the organic sheets, tapes, and the structure with fiber layers, decreases the weight of the brake pedal even more. At the same time, it allows it to showcase outstanding mechanical characteristics.

According to him, both of these features are critical for any safety component. Enthusiasts should know that the company is presently manufacturing four variants of the plastic brake pedal. Besides this, the company is optimizing load paths for different component versions so that they can adjust with diverse directions of torsions.

Porsche Gmbh Composite technology

Presently, the company makes large scale production of these brake pedals using an automated process that incorporates short-cycle times hybrid molding. The method involves Tapex insert integration followed by tape draping with the assistance of an injection molding process.

The primary production stage involves tape alignment with the usage of optical measuring systems followed by tape positioning on Tepex insert for welding purposes. The injection molding process consists of making this assembly thermoform and using the polyamide 66 for back molding. We eagerly await to hear reviewer feedback on the new plastic brake pedal and its capabilities. Stay tuned for more updates on electric vehicles and automakers.

Share this:  
#2020PorcsheTaycan#Turbo#TurboS#Turbo4s#Price#worldcaroftheyear#electric#hybrid