HANNOVER MESSE Materials Forum Novel Fibre Reinforced Polymers for the Automobile Interior Lightweight Structural Components in a Multi-Material Design Hannover, 10 th April 2013 R. Matheis, T. Schulte, L. Eckstein Institut für Kraftfahrzeuge - RWTH Aachen University A. Köver Johnson Controls Automotive Seating Slide Nr. 1
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 2
CO 2 emissions [g/km] Motivation CFRP in Automotive Applications Diminishing reserve of fossil fuels Increasing legislative environmental constraints Electric vehicle: Optimising range (compensate weight of battery) Reduce mileage independent of powertrain by lightweight design Steels Current Situation CFRP Pot. Weight red.: Limited Highest Maturity Level: High Low Material Cost: Low Very high CO 2 -Emission Legislation in the EU Need for Research Reduction of material and manufacturing cost of CFRP components Lower cycle time for potential series production Integration of steel inlays into fibre components for structure connection Development of a component showing feasibility of the material concept 240 200 160 120 80 40 0 1995 185 g/km (1995) 177 g/km (2000) Actual CO 2 fleet emissions in the EU 140 g/km (2008) European Union legislative emission regulations 130 g/km (2015) 95 g/km (2020) 2000 2005 2010 2015 2020 Slide Nr. 3
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 4
The CAMISMA Project Project Overview Boundary Conditions CAMISMA carbon fibre amid metallic structural interior component using a multi material approach Funded by the German Federal Ministry of Education and Research (BMBF) Project duration: 01.04.2011 to 31.03.2014 Targets Development of innovative and competitive fibre composites for vehicle lightweight structures Reduction of CO 2 -emissions during the production of CFRP by using fibre manufacturing by-products Cost-competitive manufacturing of fibre composite components (low cycle times and production cost) Slide Nr. 5
The CAMISMA Project Work Packages Production of preforms Production of laminated tapes Design of a multi material structure Manufacturing and functional improvement Economic and environmental analysis Recycling and processing of carbon fibre side products Continuous tape production In-situ polymerisation Identification of material properties Development of a backrest structure FEM analysis Combination of injection moulding and thermoforming Validation of process on demonstrators Cost analysis of the lightweight concept Life cycle assessment Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco² Slide Nr. 6
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 7
Development and Production of Novel Fibre Tapes Production of pre-forms Production of laminated tapes Carbon fibre cuttings of different lengths are homogenised by cutting compacted to mats of non woven fabrics by aerodynamic formation Filament spreading of unidirectional (UD) rovings Image Sources: ITA RWTH Aachen University, Science-to-Business Center Eco² Continuous impregnation of preforms (UD fibres and non woven fabrics) In-situ polymerisation with thermoplastic Polyamide 12 matrix Increased adhesion of matrix to fibres Low cycle time Enhanced economic viability Slide Nr. 8
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 9
Design of a Multi Material Structure Development Progress Targets: Targets Development of an automobile seat backrest structure Combination of non woven and UD CFRP tapes with injection moulded GFRP, directly integrating a steel inlay Weight reduction of 40 % compared to a reference Feasibility and economic viability of production progress Fulfilling passive safety requirements (front/rear impact) Dynamic Load Cases Extensive Use of FEM 0 Identification of material parameters and validation of appropriate material models 0 Simulation of rear and front impact (static/dynamic) +45-45 Element Density Dicke [mm Static Analysis Production Process Optimisation of GFRP topology and tape layers Slide Nr. 10
Design of a Multi Material Structure Multi Material Design Multi-Material Demonstrator Non Woven Fabric Tapes GFRP Injection Mould Back Panel Reinforcement Rips UD Fabric Tapes Steel Local Reinforcement Image Sources: Science-to-Business Center Eco², ITA RWTH Aachen University, HBW-Gubesch Thermoforming GmbH Recliner Connection Slide Nr. 11
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 12
Manufacturing of a Demonstrator Component Manufacturing Process Spri-Form Process Injection moulding and thermoforming as one process step Steel inlay integrated by overmoulding Proof of Feasibility Proof of concept by producing a sample component Manufacturing a cut-out of the final demonstrator (Currently in preparation) Standard Injection Moulding Machine Injection MouldingMaterial For Function Integration Organic Sheet Manufacturing of the full back rest demonstrator heated Organic Sheet Heating SpriForm Tool Forming Process Image Source: HBW-Gubesch Thermoforming GmbH Slide Nr. 13
Agenda Motivation The CAMISMA Project Development and Production of Novel Fibre Tapes Design of a Multi-Material Structure Manufacturing of a Demonstrator Component Summary and Outlook Slide Nr. 14
Summary and Outlook Summary Filament spreading of unidirectional (UD) rovings Production of non woven fabric tapes using fibre cuttings In-situ polymerisation with thermoplastic Polyamide 12 matrix Material tests depicted feasibility and good structural properties of novel composites Successfully integrated novel fibre products in virtual development process Virtual design of an automobile backrest Fulfilling safety requirements Weight reduction of 40 % Economic manufacturing Proof of feasibility of spri-form process Outlook Implementation of continuous impregnation machine Production of backrest cut-out Production of full demonstrator Validation of the requirements Special focus on crash tests Cost analysis Life cycle assessment Slide Nr. 15
Thank you for your attention! Slide Nr. 16
Contact Dipl.-Ing. Ralf Matheis Dipl.-Ing. Axel Köver Forschungsgesellschaft Kraftfahrwesen mbh Aachen Steinbachstraße 7 52074 Aachen Germany Johnson Controls Automotive Seating Industriestraße 20-30 51399 Burscheid Germany Email Internet matheis@fka.de www.fka.de Email Internet axel.koever@jci.com www.jci.com Slide Nr. 17