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JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 56

FEATURE “Automotive” g…/… Thoughts on automotive construction: opportunities for thermoplastic composites dead or in very bad shape for the rest of their lives, because internal organs can burst. The energy to be absorbed increases proportionately with the weight of the vehicle and the square of its velocity: the kinetic energy = 1/2 mV² (m = mass, V = velocity). What is never said is that the heaviest and fastest cars are also the most deadly in case of impact with a fixed obstacle. (Of course, every driver has the illusion of being better than the others and of driving in a Formula One race!) The Traban. E-coating tyranny Once the problems associated with processing and recycling long-fibre-reinforced composites are resolved, it is likely that car builders will eventually escape from the “tyranny” of E-coating and switch to the use of synthetic materials for car bodies to save on weight and lower prices. For now, (assuredly) skilled deep drawing specialists with mechanical backgrounds still prevail in that area. Besides changing ingrained driver habits (including with respect to observance of speed limits!), we need to acquaint designers with functional value analysis, which is the only realistic concept from the consulting world that can be applied to all the many techniques used in this industry. Table 3: Background on the advance of synthetic materials in auto body making. reinforced composite bodies on sedans, while Chrysler’s Composite Concept Vehicle (CCV) prototype gives an idea of what the future might hold: four short-glass-fibre-reinforced PET body-shell panels that are injected on an 8,000-ton press. Three things must be achieved in order to make more progress: - greater stiffness in large, heavy parts by using composites reinforced with long fibres at least 3 mm long, and in structural parts using long or continuous fibre reinforcement; - using a reprocessable or recyclable material – and therefore a thermoplastic – in automotive mass production; - increasing productivity; i.e. reducing cost prices. Table 4: Chrysler’s project: to create a plastic car inspired from the Citroen 2CV. Injecting a side pillar Side pillar Interior floor pan Full body Injection cycle Overall Assembly time Estimated consumption Adhesive-bond assembly of the 2 side pillars = 16 kg = 32 kg = 96 kg = 3 min = 1,100 parts, compared to 3,000-4,000 for a standard car = 6.5 hours, compared to 15-20 hours for a standard car = 4 litres/100 km Around 1955 1960’s Chevrolet Corvette (body understructure) Citroen DS (roof) Renault Alpine (entire shell) Matra and Porsche (niche vehicles) Renault R-5 (front and rear bumpers): launched the large-scale use of composites in automotive structural applications, heavily contributing to the success of the vehicle when builders were afraid to depart from chrome bumpers Citroen BX (hood and hatchback) Matra Espace (complete shell): helped to validate the concept of an all-TS-composite minivan body MCC Smart (all-TP-plastic shell) 1982 1984 1998 There should be a special note on the Citroen Mehari, which was the first medium-production-run car with a thermoplastic (thermoformed ABS) body, mounted on a metal chassis. This concept will likely make a comeback with improvements in the future. French drivers in coastal areas still regret this simple car, which was highly resistant to the aggressive saline environment. Another pioneer was the Traban, a car with a two-stroke motor and body made of phenolic resin reinforced with cotton fibres. Three million of these cars were built between 1958 and 1990 in the ex-GDR (German Democratic Republic). Although it was the first mass-produced car with a composite body, the Traban was nevertheless scorned in Western Europe. In the United States, the Fiero and Saturn models mass-produced by General Motors demonstrated the potential for fibreglass- There will certainly be errors committed in plastic body making, and some of the suggestions made here will perhaps be invalidated. These are proffered mainly as not-unrealistic ideas that could be developed by plastics processors with the capability, and who could most benefit from them. Surely some of these ideas will come to fruition in the near future. We can only hope that the practice of painting non-rusting materials will be abandoned, as it raises cost and makes recycling more difficult. We can also hope that the principle of sustainable development advocated by auto makers is not just a myth! In the long run, the only uncertainty is on who will produce these plastic shells: equipment manufacturers or auto makers? Given that equipment manufacturers already account for 70% of the cost of a vehicle, the relationship between the two will certainly have to be readjusted. Contact: msreyne@aol.com jec composites magazine / No45 November-December 2008

JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008

Cover
Editorial
Market Place
Advertisers
CONTENTS
NEWS WORLDWIDE
- Companies
 - Innovations
 - Agenda of events
 - Innovations
BUSINESS
 - Market survey
 - Trends: Productivity
 - Human Capital: Designer
FEATURE - AUTOMOTIVE
 - Design
 - Raw material
 - Thermoplastics
 - Prepreg
 - Structural materials
 - Foam materials
 - Induction
 - Software
- Lighting
USERS' PLATFORM
 - Composites in the world
 - Successful partners
- Applications
KNOW-HOW
 - Biopolymer
 - Processing
 - Modelling
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Cover
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 2
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Editorial
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Market Place
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - CONTENTS
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 7
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Companies
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 9
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Innovations
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 11
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 12
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 13
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 14
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 15
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 17
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Innovations
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 19
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 20
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Market survey
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Trends: Productivity
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Human Capital: Designer
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - FEATURE - AUTOMOTIVE
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Design
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 27
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Raw material
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 29
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 30
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 31
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 33
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 34
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 35
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 36
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 37
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 38
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 39
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 40
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Prepreg
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 42
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 43
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Structural materials
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Foam materials
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 47
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 48
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 49
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Induction
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 51
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Software
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Lighting
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 55
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 56
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 59
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Successful partners
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 61
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Applications
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 63
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 64
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Biopolymer
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 67
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 68
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 69
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Processing
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 71
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 72
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Modelling
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 74
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 75
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 76
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