composite technologies contribution to the automotive. composite... · why use composites in...

Composite Technologies Contribution

to the Automotive

July 2017 JEC Bangkok

Lolatte XIA

Where We Are Today

07/07/2017 2

Agenda

07/07/2017 3

Introduction

Opportunities for Light Weight Solutions

Innovative Composite Body Solutions

The Key Challenges of Light Weight Solutions

GHG emission Fraction

07/07/2017 4

Transportation accounts for 15% in all GHG emissions

Land transport is the main cause in all transportation GHG emission

20%

24%

15%

8%

13%

17%

3%

70.9%

15.3%

12.5%

0.6%

0.7%

GHG Emission Fraction in All industry GHG Emission Fraction in all transportation

Source: IAS

07/07/2017 5

Global vehicle production and marketing break through 108 millions in 2024 by forecast

The fast growing market and high vehicle inventory is causing serious environmental

issues and resources issues

Mill

ion

Veh

icle

s Growth of Vehicles and Consequences

Source: IHS

7/7/2017 6

Compliance to increasingly strict emissions & fuel

economy regulations

+

Compliance to challenging vehicle safety regulations

+

Increasingly challenging cost and margin pressures

The Key Challenge

7/7/2017 7

Key Market Drivers & Trends

Global Carbon Dioxide standards are becoming increasingly challenging

Region: 2015: 2020:

EU 130g/km 95g/km

Japan 137g/km 105g/km

China 161g/km 117g/km

US 158g/km 121g/km

7/7/2017 8

Key Market Drivers & Trends

• Vehicle crash safety standards in the world are becoming more and more strict year by year,

such as C-NCAP/E-NCAP/J-NCAP/A-NCAP/IIHS etc…The same trend is that not only

increasing crash speed but also requiring the high strength of vehicle body to protect

passengers.

• The visibility of vehicle is becoming more attractive to customers, so larger windscreen and

sunroof is very popular in current vehicle designs,this means smaller cross section of pillar joint

to address design style but cause a big challenges to vehicle body stiffness.

• Driving more comfortable requires high stiffness vehicle body to reduce vibration.

Agenda

07/07/2017 9

Introduction




How to Tackle Issued by Increased Vehicles

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5-10g/km of CO2 emission would be saved while reduce 100kg weight per vehicle

The fuel-efficient would be improved 6-8% while reduce 10% weight per vehicle

0.3-0.6 L petrol per 100km would be saved while reduce 100kg weight per vehicle

Light Weight Solutions !!!

Source: IAS

How to Tackle Issued by Increased Vehicles

07/07/2017 11

Light Weight Design of Vehicle

Battery Technology

Vehicle Reset

Control System

Powertrain System

46%

30%

30%

23%

11%

Light weight design of vehicle accounts for largest proportion among all solutions. It is the

most efficient way for improving emission and saving energy.

Agenda

07/07/2017 12

Introduction




Miscellaneous Light Weight Design

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Reduce the thickness of metal part of vehicle body while increase metal grade for

keeping equal strength

Optimize structure design

HS steel and HS aluminum in key area of vehicle body

Casting ,Hot Stamped, Rolled and extruded profile structure replace several stamped

parts in key area of vehicle body

Advanced Joining methods for BIW

Composite material for BIW

Challenges of Light Weight Vehicle

07/07/2017 14

Light Weight is good for environment, energy consumption, driving stability

Traditional light weight solutions bring challenges like high cost and performance loss.

Composite light weight solutions are highly required based on the principles that light

weight solution maintain or improve the performance with limited cost increasement.

Light Weight

Emission

Energy

Durability

Dynamic

Braking

Cost Safety

NVH

The Trend Of Light Weight Solutions

07/07/2017 15

Hybrid Body Construction

– Steel to aluminium

– Steel to composites

– Aluminium to composites

Why use Composites in Automotive?

07/07/2017 16

Provide high strength and good

crash worthiness with much lower

weight to:

– Reduce vehicle emissions in

gasoline & diesel vehicles

– Extend electric vehicle range

– Improve vehicle acceleration,

performance & handling

– Compliance to crash

regulations with lower weight

vehicle body in white

Allow for production of large single

components, providing new

options in vehicle design and

functional integration

7/7/2017 17

L&L Products Biography

Established since 1958, L&L Products

is a privately owned company with

operations in 10 countries, focused

on safety, light-weighting &

acoustic systems for cars, aircraft

and commercial vehicles

L&L Composite Body Solutions

(CBS) technology combines novel

expandable structural adhesive and

composite technology and has been

employed by many OEM’s to enhance

safety, weight & acoustics

performances

L&L Bond structural adhesives

provide outstanding adhesion to all

commonly used substrates, and are

customized to meet all common

processing, performance and

durability requirements

Composite Body Solutions

07/07/2017 18

Composite Reinforcement

Innovative Composite Bond-Dry Structure Film

CBS®


Innovative Composite Adhesive- Structure Filling Adhesive

Innovative Composite Bond-RTC


07/07/2017 19



CBS®





07/07/2017 20


One type of Reinforce technology that is heat activated

and consists of an expandable structural adhesive used

to bond individual sections of the body structure to create

a unified macro-structure.

Usually consist of a formulated expandable structural

Foam material, combined with a engineered carrier

Technologies enable weight to be reduced, while

maintaining or improving vehicle durability, stiffness, and

crashworthiness.


How Composite Body Solution works

07/07/2017 21

Heat activated expanding adhesive and an engineered carrier fills cavities and bonds

individual load bearing members to create a unified structure with significantly improved

stiffness and strength attributes.

“Buckling” CBS keeps the stability of the

cross section

High strength expandable

adhesive

Carrier

- Polymer

- Metal

- CF

Without Composite Body Solution With Composite Body Solution


Solutions

Base Steel Composite Body Solution

Empty Cavity Increase thickness

of steel panel Composite Body Solution

Weight(kg) 2 3.2 2.6

Strength(kN) 6 20.8 25.4

Light Weight Efficiency(kN

/kg) 3 6.5 9.8

07/07/2017 22

For Strength For Stiffness

Max.Force:25.4kN

Max.Force:20.8kN

Max.Force:6kN

Solutions

Base Steel Composite Body Solution

Empty Cavity Increase thickness of

steel panel Composite Body Solution

Weight(kg) 7.47 9.84 7.89

Stiffness(N/mm) 926 1818 2025

Light Weight Efficiency(N/mm.kg

124 185 257


How Composite Body Solution works

E-Coat Process

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Attaching CBS part to sheet metal

CBS adhesive expands then

bonds to the body structure

Section (steel) is

e-coated

CBS allows e-coat

flow thru the section

CBS installed in body shop


07/07/2017 24

NVH (durability)

NVH (stiffness)

Typical application areas:

Pillars

Closures

Roof

Rocker

Cowl Bay

Under body

NVH solutions for optimizing your BIW：

Global stiffness

Local stiffness

Durability

Torsion/bending mode

Torsion/bending stiffness

Improve NVH and durability for lightweight body design


Typical Application-Why Composite Body Solution required

07/07/2017 25

BIW (With Battery) Current Status: Tosional Frequency:40.19Hz (Target 40)

Bending Frequency:41.2Hz (Target 40)

Requirement: 4kg weight reduction

Steel Solution: Investigate Sensitive area:

1.Add steel brackets in D ring joint ( +1.2kg)

2.Reduce thickness of steel parts ( - 4.2kg)

Effect: Weight Reduction: 3kg

Tosional Frequency: 37.9Hz

Bending Frequency: 39.1Hz

ISSUES: Achieved 3kg weight reduction but performance

loss is unacceptable

Add steel bracket in D ring is a big challenge for

assembly process

30+ spot welds added will increase much cycle

time


07/07/2017 26

CBS Solution: Investigate Sensitive area:

1.Add CBS in B/C/D Ring ( +2.8kg)

2.Reduce thickness of steel parts ( - 7.0kg)

WINNER! Achieved 4kg weight reduction While maintain

performance

Easy Assembly process,clips or push-pins for

attachment

30+ spot welds saved compared with steel solution

Cycle time saved compared with spot weld process

Effect: Weight Reduction: 4.2kg

Tosional Frequency: 40.19Hz

Bending Frequency: 41.10Hz



07/07/2017 27

L&L Solution

1.4 kg/vehicle mass savings

0.68 kg/part 1.38 kg/part

Sub frames & Cradle Mounts

• Adhesive spreads the loads for improved

durability

• Structural insert bonds to the nut and the

four sides of the section

• Improve local stiffness

• Mass reduction

• Steel solution traditionally consist of thick

steel components due to the high stress

• Adhesive eliminates the welding heat

affected zone



Improve structure safety for lightweight body design

07/07/2017 28

Front crash

Side impact

Rear crash

Roof crash

Small overlap front

Typical Safety Regulations:

FMVSS

IIHS

ECE

NCAP

Typical application areas:

Pillars

Rails

Floor

Rocker

Typical Safety Ratings:


07/07/2017 29

Current Status: A Pillar broken during front offset impact

Requirement: Need improve structure strength of A pillar to meet

crash target

Steel Solution:

1. Hot stamped Reinforcement in A pillar ( +1.3kg)

2.Insert Structural Foam on steel part as connection

due to spot weld is unavailable.

Effect: 1.CAE shows unacceptable performance with Steel insert

2.Proposal failed ,no opportunity to test in real vehicle.

ISSUES: Hot stamped steel still cannot solve big deformation

issue in A pillar.

Weight is too heavy

Need 4 months product development cycle.

Tool cost is too expensive for this hot stamped part.



07/07/2017 30

CBS Solution: 1. CBS Reinforcement in A pillar ( +0.9kg).

Effect: 1.CAE show acceptable performance with CBS

2.Proposal Succeeded, crash test in real vehicle

show acceptable result.

Winner: CBS solved big deformation issue in A pillar.

0.8kg/vehicle mass savings

Only 2 months product development cycle.

Injection Tool cost is much cheaper than hot stamped

part.



07/07/2017 31

Evolution of Composite reinforcement


Steel Solution:1.087kg

1st Gen CBS:0.47kg

PA66GF30 Carrier

2nd Gen CBS:0.28kg

CFRP Carrier

Require Improve the section force of B

pillar to 40 kN

From Steel reinforcement to 2nd

Gen CBS ,mass added from 1.087kg

to 0.28kg to achieve same target


07/07/2017 32




CBS®



Structure Filling Adhesive

07/07/2017 33

The Structure Filling Adhesive is formulated

to provide superior ductility and deliver a

high performance structural bond. With

expansion of 200%~300%, has the unique

ability to provide structural bonding while

bridging a typical and varying design gaps.

Key Product Attributes

• Gap Jumping

• Fracture Toughened Technology

• Structural Reinforcement

• Dissimilar Material Joining

• Increased Durability & Stiffness


Typical application-Structure Filling Adhesive

07/07/2017 34

Roof panel

Roof Frame

Body Side

Panel

Light weight Adhesive:

1.Bonding roof frame and roof rail panel

2.Absorb big tolerance between two assembly-sunroof and body side

3.Gap Jumping -3mm thickness in green state and 6mm after cured

4. Material made as tape,stable dimension,no need equipment for

operation

5. Increased 1.2Hz torsional mode with 0.1kg mass added. Compared to

steel proposal light weight ~1kg

Roof Rail

Panel

Laser

Welding


07/07/2017 35

Tailgate: 1st Torsional mode Target: 28Hz

Baseline: 1st Torsional mode :23.27Hz

Failed

Steel Solution: 1st Torsional mode:24.95Hz

Failed

Add mass:1.2kg

Thicker steel reinforcement


Solution: 1st Torsional mode:28.97Hz

Winner!

Add mass:0.05kg

Typical application-Structure Filling Adhesive



07/07/2017 36




CBS®



• As an evolutionary development from structural foams

and tapes, L&L Bond dry structural adhesives cure in

the heat of the e-coat oven, bonding a wide variety of

substrates.

• As opposed to conventional structural adhesives, which

are liquids or pastes before they are cured, L&L Bond

dry structural adhesives are solid and dry-to-touch at

room temperature.

• High Strength and stable dimension with varies thick

from 0.3 to 1mm.

• With an option of fleece material integrated to increase

strength

Dry Structural Adhesive

Dry Structural Film

07/07/2017 37

Steel

e- H2O

Ex.: Bonded Carbon-Steel assembly: Galvanic corrosion insulation

Localized contact possibility due to part geometry or positioning: Electron exchange still possible. St

and

ard

pu

mp

able

ad

hes

ive

Stru

ctu

ral a

dh

esiv

e

film

wit

h g

lass

fle

ece

Steel

Carbon H2O

No contact due to part separation by physical glass insulation: No electron exchange possible.

Risk of part corrosion

No Part corrosion

Why need dry structural adhesive

Dry Structural Film

07/07/2017 38

Typical applications

Rear Mirror

Bonding

Spacer while fastening bolts

Trunk Hinge

Bonding

Sealing

B Pillar

Bonding

Spacer while compress CFRP

Front Lamp

Bonding

Al-Al

Front Lamp

Bonding

Al-Al

Dry Structural Film

07/07/2017 39


07/07/2017 40




CBS®



• Automotive interior applications offer a

number of opportunities to bond composites

to other substrates:

• Dashboard retainer to composite CCB

• Dashboard retainer to composite topper pad

• Knee bolsters & glove box door assemblies

• HVAC unit

• Door panel assembly

Interiors Bonding-RTC

RTC

07/07/2017 41

Exteriors Bonding-RTC

RTC

07/07/2017 42

• Applications include fenders, tailgates, boot lids & closures

Summary

07/07/2017 43

Where you can find the successful composite body solutions…

……

Thank you for your attention !

• Questions ?

• Suggestions ?

07/07/2017 44

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