Modern vehicle development is characterized by numerous boundary conditions concerning energy, materials and cost issues, as well as global and local environmental requirements. Particularly, these necessary measures for climate protection require a clear increase in energy efficiency and a drastic reduction in CO 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, 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. So in just one closed 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 is possible to manufacture. That process can also be used for large batch production. 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.


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    Title :

    New Fiber-Reinforced Thermoplastic Metal Hybrids - a New Technology Concept for a Highly Crash Loaded Lightweight Electric Vehicle Component


    Contributors:
    Täger, O. (author) / Ehleben, M. (author) / Lohmann, J. (author) / Kharchi, K. (author) / Schweizer, K. (author) / Kroll, L. (author) / Meyer, M. (author) / Nendel, W. (author)


    Publication date :

    2014


    Size :

    4 Seiten, Bilder



    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English





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