In a comprehensive joint study, composite material manufacturer Henkel and engineering consultant RLE International inspected and verified the potential of high-performance structural foams to reduce the weight of automotive bodies and closures. Studies have shown that compared with traditional all-metal structures, fiber-reinforced polymer components with structural foam ribs and reinforcement materials can save more than 40 kg of weight per vehicle.
Body parts, especially closures, have always been the key to lightweighting in automotive engineering because they are one of the largest components in automobiles. Even if the thickness of the steel is reduced by one tenth of a millimeter, it means that the overall weight is reduced by several kilograms, which has a positive impact on fuel or electricity consumption and carbon emissions. However, in most modern cars, when it comes to steel, engineering limitations on thickness are definitely a challenge, so further thickness reductions may create problems in meeting the required mechanical strength and collision protection.
David Caro, Head of Global Engineering, OEM Design, Automotive and Transportation at Henkel, said: "In a completely new approach, we have studied to overcome these limitations by replacing traditional all-metal design with hybrid fiber and structural foam reinforced polymer solutions The possibility of our research confirms that we can optimize the stiffness of fiber-reinforced plastic frames or carriers with selective foam ribs and reinforcing materials at a competitive cost without sacrificing safety. Further significantly reduce the weight. "
This hybrid material is characterized by a solid frame or carrier made of high fiber reinforced polymer (FRP) and selective reinforcement material (Henkel s Teroson EP structural foam). Teroson EP structural foam is a commercially available epoxy-based material that provides high strength and rigidity in extremely light conditions. The foam is injected into the carrier at a predetermined section, expands in an electronically-coated oven, and creates a rigid connection between the hybrid assembly and adjacent components in the body-in-white.
This material can withstand ordinary car washing and phosphating solutions as well as electro-dipping coatings without curing. Then according to the specific foam grade, curing takes place in 15 minutes or less.
This comprehensive project includes all the main body and closing parts of SUV vehicles, from bumpers, mudguards, pillars and doors, to rocker panels, side panels and rear doors. Tobias Wigand, project manager of the new business development department at RLE International, explained: "The final design was based on a wide range of finite element engineering and crash simulations based on standard specifications in several consecutive optimization cycles. In some cases, such as side doors Compared with the original all-aluminum design, our hybrid structural plastic and foam solutions can even exceed the expected performance. "
The crash simulations carried out in the study strictly adhered to extremely demanding international automotive standards, such as the European New Car Assessment Program (Euro NCAP) and the Highway Safety Insurance Institute (IIHS) at speeds of 64 km / h and 50 km / h, respectively. The offset and small overlap frontal crash test. According to the US NCAP specification, the side (or rod) crash performance is tested at a speed of 32 km / h. According to the US Federal Motor Vehicle Safety Standard (FMVSS) No. 301, a rear collision scenario is simulated by moving an obstacle at a speed of 60 km / h on a fixed test vehicle. Using another IIHS test standard to establish the compression performance of the top plate.
Overall, the hybrid design combined with Henkel's Teroson EP structural foam was found to pass all these tests well within the limits of deformation and intrusion, while providing a lot of weight compared to traditional all-metal components save. Henkel and RLE International are providing their hybrid structure design technology as a comprehensive joint approach from concept to launch and series production to ensure the safety and sustainability of all development, engineering and material processes. Each design is fully designed and optimized according to customer specifications and applicable industry standards for all relevant crash load conditions.