Plastics & Composites Solutions for the Tesla Roadster

Transcription

1 1 Plastics & Composites Solutions for the Tesla Roadster Barrie Dickinson, Tesla Motors September 15, 2009

2 2 - Overview Tesla Motors Electric Performance Our Industry Leading EV Powertrain Drive Towards Mass Market EV s Model S Unveiled Roadster Case Studies Example 1 Carbon RTM Body Panels Example 2 Carbon Reinforced Injection Molded Hood Frame

3 3 - Tesla Motors Disruptive technology car company 100% electric powertrain Leading green car brand 365 employees Best of Silicon Valley and traditional auto industry Offices and stores worldwide STORES Los Angeles, CA Menlo Park, CA New York, NY Munich, Germany London, UK Seattle, WA In Process: Chicago, IL Miami, FL Washington, D.C. Toronto, ON, Canada Monaco Zurich, Switzerland FACILITIE S TAIPEI, TAIWAN Motor Manufacture SAN CARLOS, CA Corporate HQ Battery Manufacture AUBURN HILLS, MI Supply Chain Office HETHEL, UK EU Sales US Glider Manufacture EU Vehicle Build LOS ANGELES, CA Styling Studio

4 Acceleration from 0 to 60 mph ( Sec.) 4 - High Performance Electric Performance High performance sports cars Fuel Cell High Mileage High Efficiency Gasoline Hybrid Diesel Well-to-Wheel Energy Efficiency (km/mj) Tesla Roadster Porsche Carrera GT Lamborghini Murcielago Dodge Viper SRT-10 Saleen S7 Porsche 911 Turbo Coupe Ferrari Maranello Chevrolet Corvette Z06 Lotus Esprit V8 Panoz Esperante Nissan 350Z Toyota Celica Nissan Maxima Ford Taurus Toyota Camry Subaru Legacy Honda Civic VX VW Jetta Diesel Honda CNG (nat. gas) Honda FCX (fuel cell) Toyota Prius (hybrid)

5 Acceleration from 0 to 60 mph ( Sec.) 5 - High Performance Electric Performance High performance sports cars Fuel Cell High Mileage High Efficiency Gasoline Hybrid Diesel Well-to-Wheel Energy Efficiency (km/mj) Tesla Motors Electric Vehicles Tesla Roadster Porsche Carrera GT Lamborghini Murcielago Dodge Viper SRT-10 Saleen S7 Porsche 911 Turbo Coupe Ferrari Maranello Chevrolet Corvette Z06 Lotus Esprit V8 Panoz Esperante Nissan 350Z Toyota Celica Nissan Maxima Ford Taurus Toyota Camry Subaru Legacy Honda Civic VX VW Jetta Diesel Honda CNG (nat. gas) Honda FCX (fuel cell) Toyota Prius (hybrid)

6 7 - Drive Toward Mass Market EVs HIGH PERFORMANCE ZERO EMISSIONS 200+ MILE RANGE PROPRIETARY TECHNOLOGY

7 8 - Model S Unveiled March 26, 2009 for 2012 MY

8 9 - Model S Unveiled March 26, 2009 for 2012 MY

9 10 - Model S Unveiled March 26, 2009 for 2012 MY

10 11 - Model S Unveiled March 26, 2009 for 2012 MY

11 12 - Roadster Case Studies - 1 Example 1: Carbon Reinforced Epoxy Exterior Body Components.

12 13 - EV s and Weight 100% plug-in EV battery packs add considerable weight, especially for 200+ mile driving range. Roadster battery pack has 6831 individual Li-Ion batteries and weighs over 900 lbs. Offsetting weight reductions are vital to maintaining high performance and high range Roadster body panels and closures needed to be as light weight as possible yet stiff extensive use of carbon fiber. Carbon Fiber epoxy RTM process selected for faster cycle times and higher production volumes from one set of tools, plus lower piece cost

13 14 - Roadster composite panels and assemblies Production capacity and tooling planned for 1500 vehicles per year 30 sets of panels per week needed normal time, 40 sets per week needed at max rate Seat Shells LH and RH Windscreen Surround Hardtop, Optional Door Outers and Inners LH/RH Roll Hoop Cover Body Sides LH and RH Hood Panels Front Bumper Armature Front Fenders LH and RH Tailgate Inner and Outer Bootbox

14 15 - CF Epoxy RTM Body Panel Construction Typical layup and processing for Tesla Roadster CF Body Panels Outer layer is continuous non-woven glass fiber veil or tissue 2 nd layer is Zoltek Panex 35 carbon fiber +45º/-45º unidirectional 50K Tow fabric, tricot stitched 3 rd layer is continuous non-woven glass for infusion Unifilo 4 th layer is Zoltek Panex 35 carbon fiber -45º/+45º unidirectional 50K Tow fabric, tricot stitched Upper and lower CF unidirectional fabric layers mirror each other to balance stresses and minimize distortion RTM resin is 12,000 to 15,000 cps BPA epoxy mixed at tool injection port with amine hardener Cure time in mold is 20 minutes. Finished part nominal thickness is 1.6 mm Low modulus urethane adhesive bonds all panel reinforcements and inners to outers All exterior painted composite parts primed with high film build DuPont 5150 urethane 2K primer Topcoat system is DuPont Cromax low bake waterborne 1K urethane with Dupont 2K acrylic Chromaclear HS

15 16 - Tesla CF Epoxy RTM Material Properties Flexural long beam test per ISO mm x 25 mm thickness mm Flexural short beam test per ISO mm x 8 mm thickness mm Shear Strength..35 MPa Flexural Strength 471 MPa Young s Modulus 25.8 GPa

16 17 - Roadster Body Panels Sourcing Timeline Initial production tooling laid down with a supplier close to the manufacturing site in Norfolk, UK. Technology proved harder to implement than expected. In Oct 07, 4 months prior to Job#1, supplier withdrew from program. Search for new supplier led to Sotira (part of French Sora group) Tools moved to France to allow production to commence, all exterior panels redesigned, retooled and introduced into production within 10 months.

17 18 - A Class Panel Tooling and Lay-up

18 19 - A Class Panel Tooling and Lay-up

19 20 - A Class Panel Tooling and Lay-up

20 21 - A Class Panel Tooling and Lay-up

21 22 - CF Epoxy RTM Parts with Foam Cores Bootbox Front bumper armature Tailgate outer panel Door outers Body sides (LH and RH) Seat shells

22 23 - Roadster Case Studies - 2 Example 2: Carbon Reinforced Injection Molded Hood Frame

23 24 - Carbon Reinforced Nylon Hood Structure IXEF % carbon-fiber reinforced polyarylamide compound which exhibits extremely high strength and stiffness good surface gloss excellent creep resistance lower density than glass-fiber reinforced engineering resins. IXEF3008 Material Properties Flexural Strength: (ISO 178): 360MPa Flexural modulus (ISO 178): 23GPa Young s Modulus (ISO 527): 26GPa Weight relative to wrapped foam part Carbon wrapped foam: 1940g Injected IXEF: 1790g

24 25 - Thank You Any Questions?