JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 29

minutes depending on the part size, cycle times are still rather long with conventional matrix systems.

RTM demonstration part: roof module
The first demonstration part based on the various BASF materials suitable for RTM is a convertible roof module made up of several sections in a sandwich construction with carbonfibre-reinforced cover layers and a polyurethane foam core (Fig. 8). This roof segment forms the forward part of a three-section retractable hard top (RHT) folding roof concept which was conceived and designed by EDAG GmbH, Fulda, Germany, as a feasibility demonstrator for a generic fibre composite sandwich concept with system components from BASF optimized with each other. The central layer of the demonstrator sandwich structure is a closed-cell PUR structural foam from the Elastolit D range. It serves as a low-weight separator for the laminate cover layers, resulting in an exceptionally high component stiffness. In addition, it gives the roof module good insulating properties. On the exterior, the component is protected from UV radiation and other environmental

influences by a paint that contains the BASF Tinuvin CarboProtect additive. Upscaling this to a mass production process will require a pre-formed foam insert containing all the additional inserts, covered on both sides with the chosen textile structure, which is laid into the mould and fully impregnated in a single operation. The PUR foam system specially developed for this by BASF has a high pressure and temperature resistance, as well as low density. This ensures that the foam core is not compressed during the injection phase. As a fibre composite sandwich concept, the RHT roof segment weighs 2.9 kg in total, which represents a weight reduction of more than 35% compared to an aluminium construction and more than 60% compared to a steel one, whilst offering a comparable loading capacity under all typical design loading cases for vehicle roofs.

zers would not be in series production today without the ability to predict anisotropic part behaviour reliably, especially in a crash. To design and build the seat pan for the Astra OPC, the company’s engineers provided material descriptions for the virtual design of both the CFR laminate and the overmoulded ribbed areas of the part. This knowledge will be incorporated into an extension of the Ultrasim tool, making it possible to predict the behaviour of thermoplastic composite parts with continuous fibre reinforcement. For the same purpose, the company is expanding its expertise in the prediction of part performance by incorporating representation methods and material models for steelcord composites but also for such complex CFR structures as targeted by the reactive RTM systems.

Conclusion
Light but sophisticated high-performance fibre composite components and the associated composite raw materials will be able to replace even more metal, save weight and thus reduce energy consumption and CO2 emissions still further. With regard to cost-benefit considerations, various matrix materials, fibre types, reinforcing techniques, joining technologies, predictive modelling and processing technologies are currently being developed in parallel and rigorously investigated for their suitability for mass production. Without such multiple material systems, the next leap in automotive lightweight construction will not be possible. Thus, raw material manufacturers, part suppliers and OEMs will have to work together to establish the necessary competence to tackle these complex tasks and fully exploit the potential of the different approaches. n
More information: Lightweight-design@basf.com www.plasticsportal.eu

Not without high-end simulation
For many years now, BASF has developed, enlarged and intensively applied its meantime universally applicable simulation tool Ultrasim®. Reinforced plastic parts like lower bumper stiffeners, oil pans or stabili-

Feature Automotive

Fig. 8: RTM process demonstrator in the form of a convertible roof module

No74 July 2012 /

jec composites magazine 29


http://www.plasticsportal.eu

JEC COMPOSITES MAGAZINE - Issue #74 - July 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #74 - July 2012

Cover
Edito
Point of view: Closer to the shop floor
Contents
Agenda of Events
COMPANY & BUSINESS
- In Brief
- Glass fibre
APPLICATIONS
- Pipes & tanks
- Building
MARKET
- Human resources
- Glass fibre
- Turkey
FEATURE AUTOMOTIVE
- Braiding
- Lightening
- D-LFT
- Sustainability
- RTM
- RIM
RESEARCH & DEVELOPMENT
- Design
- Fatigue behaviour
TECHNOLOGY & INNOVATIONS
- Wind
- Reinforcement
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Point of view: Closer to the shop floor
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - In Brief
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 12
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Pipes & tanks
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Building
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 15
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 16
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 17
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Human resources
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 20
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 21
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Turkey
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Braiding
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 25
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Lightening
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 27
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 28
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 29
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - D-LFT
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 31
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Sustainability
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 35
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 36
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - RTM
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 38
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 39
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - RIM
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Design
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 42
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 43
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 44
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Fatigue behaviour
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 48
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 49
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 50
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Wind
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 53
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Reinforcement
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 55
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 56
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 59
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 60
https://www.nxtbook.fr/newpress/jeccomposites/jcm2109_142
https://www.nxtbook.fr/newpress/jeccomposites/jcm2107_141
https://www.nxtbook.fr/newpress/jeccomposites/jcm2105_140
https://www.nxtbook.fr/newpress/jeccomposites/jcm2103_139
https://www.nxtbook.fr/newpress/jeccomposites/jcm-experts-digest-additive-manufacturing-2020
https://www.nxtbook.fr/newpress/jeccomposites/jcm2101_138
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_Special_Issue4
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_137
https://www.nxtbook.fr/newpress/jeccomposites/jcm2009_136
https://www.nxtbook.fr/newpress/jeccomposites/jcm2007_135
https://www.nxtbook.fr/newpress/jeccomposites/jcm_2020_Q1_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_Special_Issue3
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_134
https://www.nxtbook.fr/newpress/jeccomposites/jcm2003_133
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
https://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
https://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
https://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
https://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
https://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
https://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
https://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
https://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
https://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
https://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
https://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
https://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
https://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
https://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
https://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
https://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
https://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
https://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
https://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
https://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
https://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
https://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
https://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
https://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
https://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
https://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
https://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
https://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
https://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
https://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
https://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
https://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
https://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
https://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
https://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
https://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
https://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
https://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
https://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
https://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
https://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
https://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
https://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
https://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
https://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
https://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
https://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
https://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
https://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
https://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
https://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
https://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
https://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
https://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
https://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
https://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
https://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
https://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
https://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
https://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
https://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
https://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
https://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
https://www.nxtbookmedia.com