Modern vehicle development is characterized by numerous boundary conditions concerning energy, materials and cost issues, as well as global and local environmental requirements. Particularly, the measures necessary for climate protection require a clear increase in energy efficiency and a drastic reduction in CO2 emissions. These global problems lead to the need to develop new technical solutions on the basis of modern lightweight strategies using innovative materials and manufacturing concepts. Here, carbon fiber-reinforced polymers (CFRP) offer specific advantages. Besides their highly specific mechanical properties, CFRP offer lower tooling cost for smaller production volumes. However, many product variations within the automotive industry require new production methods with very low cycle times due to the large number of parts needed. Here, new hybrid thermoplastic CFRP concepts based on pre-impregnated semi-finished products, so-called organo-sheets, combined with metallic inserts for load carrying portions are an alternative to extend the producible number of parts. The authors have developed a new highly integrated production process on the basis of hot forming of CFRP organo-sheets combined with injection-moulding technology. This makes it possible to manufacture, in just one closed production that can also be used for large batch production, a hybrid double layer composite lightweight battery carrier with endless CFRP reinforcements, metallic inserts and long-fiber reinforced rib structures for 3D-load management and structural stiffening. This new hybrid process has been virtually designed using new process simulation techniques for the hot forming and draping of the organo-sheets. The lightweight hybrid battery carrier was manufactured under large batch conditions on a roundtable injection moulding unit at the TU Chemnitz and tested on a component test facility belonging to the Audi AG. This new hybrid composite part and the highly integrated production process developed here opens a new pathway for large-scale volume applications of automotive carbon fiber materials.
Carbon fiber-reinforced thermoplastic hybrid composites - New material concepts and process-technologies for a lightweight battery carrier
2014
10 Seiten, 10 Bilder
Aufsatz (Konferenz)
Datenträger
Englisch
Carbonfaser , Herstellverfahren , Klimaschutz , integrierte Fertigung , Polymer , Hybridverbundwerkstoff , Randbedingung , Werkzeugkosten , Automobilindustrie , Spritzgießen , Spritzguss , Halbfabrikat (Halbzeug) , Fertigungsmenge , Zykluszeit , Prüfanlage , Spritzgießmaschine , Stapelfertigung , Hybridprozess
Designing a Production-Ready Ultra-Lightweight Carbon Fiber Reinforced Thermoplastic Composites Door
SAE Technical Papers | 2021
|Locally-reinforced lightweight carbon fiber material vehicle body middle floor
Europäisches Patentamt | 2022
|