Sabic’s innovative technology is designed to replace traditional metal and thermoset panels used inside and outside the car. It will soon be commercialized in bulk-produced light commercial vehicle (LCV) separators in the global automotive market.
The partition was jointly developed by Sabic, British engineering service provider RLEinternational, Italian tool manufacturer AMAComposites, and German weaver SetexTextil GmbH.
One-time process
Vehicle panels made of UDMAX™ prepreg tape have the characteristics of strength, impact resistance, and light weight. Compared with metal parts, the weight of the inner panel can be reduced by 35%. For exterior panels, the use of composite materials can reduce weight by up to 50%. These panels are produced using efficient one-time lamination and low-pressure molding processes.
UDMAX™ prepreg tape provides a powerful solution for the automotive industry to meet the ongoing challenges of reducing weight, reducing costs and improving sustainability. Light commercial vehicle partition is the first example of this innovative material being used in structural applications. Combined with new processing methods, it can help customers achieve lighter weight challenges without affecting safety, durability, and fuel or energy usage. . Through the continuous cooperation of this unique team of engineers, designers and technical experts in the material and conversion process, Sabic intends to explore more ways to expand the application of thermoplastic composite technology.
The partitions are manufactured using high-efficiency, one-time lamination and low-pressure molding processes. The use of UDMAX™ prepreg tape can reduce the weight by 35% and meet the ISO27956 standard to ensure the safety of the goods in the transport vehicle.
Weight reduction and assembly line production
In many applications, the use of thermoplastic composites can significantly reduce weight. For separators, the traditional metal parts are replaced by laminating UDMAX™ prepreg tapes in the parts, reducing the weight by 35%. The lighter weight makes the large partition easier to handle, which helps speed up vehicle assembly.
This weight reduction is achieved without sacrificing the impact resistance of the components, which is essential to protect passengers from damage caused by cargo movement.
According to RLEInternational regulations, the partitions used to transport the fixed goods in LCVs must comply with the ISO27956 standard. The process establishment and tensile strength of UDMAX™ are the main factors to optimize the impact resistance of the separator.
Compared with metal or injection molded parts of traditional multi-piece partitions, the new method conceived, developed and designed by RLEInternational can reduce tool costs by 80% relative to injection molding tools. This savings comes from being able to replace expensive high-pressure tools with lower-cost low-pressure tools. In general, the supply cost of LCV separators can be 10% lower than the traditional metal separators it replaces.
This technology also represents a revolutionary change in automotive panel production by improving efficiency and reducing complexity. Since the molding cycle is no more than two minutes, this assembly line process avoids the traditional procurement and assembly of multiple parts from different suppliers, as well as secondary painting and decoration operations.
Setex weaves a proprietary laminate with an ultra-wide UDMAX™ prepreg core, and incorporates beauty in a single compression step. This process can also change the thickness of the panel to increase noise, vibration and harshness (NHV) levels and help reduce noise in the car. AMA composites created this tool and shaped the conceptual part.
The new technology of using UDMAX™ thermoplastic composite prepreg tape to produce sheets provides a huge opportunity for the automotive industry. An example is the electric vehicle industry, where reducing the weight of the panel can expand the driving range, and lower cost tools can reduce the capital investment of start-ups. RLEInternational stands ready to assist automakers in mastering this new process so that they can enhance their advantages on behalf of their original equipment manufacturer customers.
UDMAX™ slit prepreg tape (cross-wound)
Laminate made of UDMAX™ slit prepreg tape (fabric form)