In the first report of the automotive industry, Ford, along with Tier I Eagle and graphene supplier XG Scientific, discovered a way to use a very small amount of graphene to improve the main performance of automotive components under the hood. That is, lighter weight, better thermal conductivity, and reduced noise. The material has been referred to as xGnP graphene-reinforced polyurethane (PU) foam.
Graphene is 200 times stronger than steel and is one of the most conductive materials in the world. It is a huge sound barrier, very thin and flexible. Graphene is not economically suitable for all applications, but Ford has partnered with Eagle Industries and XG Science to find a way to use a small amount of graphene in fuel rail covers, pump covers and front engine covers to maximize Limit its effectiveness.
"The breakthrough here is not materials, but how we use it," said Debbie Mielewski, Ford's senior technology leader, sustainability and emerging materials company. "We were able to use very small amounts, less than 50 percent to help We have made significant improvements in durability, sound resistance and weight loss-applications that nobody else cares about. "
In 2014, Ford began working with suppliers to study the material and how to use it in trials of automotive components such as fuel rail covers, pump covers, and front engine covers. In general, trying to reduce noise in the cabin means adding more material and weight, but graphene does the opposite. John Bull, president of Eagle Industries, said: "A small amount of graphene has a long way to go. In this case, it has a great effect on sound absorption."
Graphene is mixed with PU foam components. Tests conducted by Ford and suppliers have shown that compared to foams without graphene, noise is reduced by 17%, mechanical properties are increased by 20%, and heat resistance is increased by 30%.
"We are excited about the performance benefits our products can provide Ford and Eagle Industries," said Philip Rose, CEO of XG Science. "Working with early adopters such as Ford Motor Company has proven graphene in a variety of applications. We look forward to extending our cooperation to other materials and further improving performance. "Graphene is expected to be put into production before the end of the year, producing more than 10 under-hood parts for Ford Ford F-150-150 and Mustang It will eventually be used in other Ford vehicles.
Eagle Industries, based in Wixom, Michigan, is a leading supplier that designs and manufactures NVH components for automotive OEMs and first-tier communities. XG Scientific, headquartered in Lansing, Michigan, USA, is a leading supplier of graphene nanoplates and custom advanced formulations to the global composites, electronics, energy and industrial markets for OEMs. XG has provided unique high-performance products to more than 1,000 customers in 47 countries.
In early October, XG Science completed the first phase of expansion at its latest 64,000 square foot facility. The expansion has increased the production capacity of graphene nanoplates by 90 tons / year, bringing the total production capacity of the facility to approximately 180 tons / year, which can produce up to 18,000 tons of advanced materials per year. The second phase of the expansion is expected to be completed by the end of the year and will allow the facility's total graphene nanoplate output to reach 400 tons per year.
The total output of graphene nanoplates in XG's two manufacturing plants currently exceeds 200 tons per year, which will double in the next three months and reach about 450 tons per year by the end of the year. Expanding to support XG's mission to continue commercializing the use of graphene in customer products in different industries.