JEC COMPOSITES MAGAZINE - Issue #81 - May/June 2013 - 37

Automotive

A lightweight bumper beam developed with an innovative
technology that incorporates skeletal reinforcements in the form of
3D-Tow into GMT (Glass Mat Thermoplastic) structures
One of the key features of this technology
is to position 3d-Tows in the optimal direction to take and distribute loads throughout
the complete component through a topological evaluation of design and load cases. This
is a unique way of benefiting from superior
mechanical performance of fibrous composites. Compression molding, one of cost
effective processing methods, was adopted
to manufacture composite structures with
the tow reinforcement. The production
of 3d-Tow was done by a fully automated
process giving low investment and production costs. 3d-Tow can be formed with any
thermoplastic resins. Polypropylene was
used for this bumper beam development.
Excellent recyclability is expected due to the
thermoplastic resin used for the part.
The values of this innovation are multiple.
First of all, it provides weight reduction of
25% (4.3kg ->3.2kg) as well as cost saving
of 10% ~ 20% 3 and more design freedom
with reducing the thickness of the composite part. The improved style ability of the
bumper system (reduced height of back
beam without sacrificing its performance
could lead to less protruded appearance of
bumper.) is also a major benefit. The enhanced collision performance provides less
chance of damaging parts in the rear of passenger cars such as truck lid and tailgate (this
may reduce repair expanse by collision.).

Finally, it is suited for high volume production and increases fuel efficiency due to the
weight reduction. It is also corrosion free.
The development phase had a target of 2014
launching for two passenger cars with optimized design and respect for weight, collision performance and cost.- The bumper
beam was then prototyped. Finally, collision
safety was evaluated based on IIHS 10km/h
full barrier test (Passed). The team is currently working on cost and preparing for
serial production. Concerning the market
potential, the need of technologies for cost
and weight saving is immense, especially in
the automotive industry. The technology of
3d-Tow reinforcement covers both and thus
has a very strong potential for high volume
production in the automotive industry. The
skeletal tow reinforcement can be incorporated into already available molding technologies, such as injection
or compression moldings.
This technology can be
used for structurally loaded
parts in automobiles, for examples, front/rear bumper
beam, seat structure, frontend-module carrier, and so
on. It will also have benefits
in other areas such as within
the sporting or consumers
goods area.

60 Ton load capacity composite manhole cover
Everlast Composites has developed a
60 Ton load capacity composite manhole cover with frame and 40 ton load
capacity gully grating with frame using
optimum quantity of glass fibers and
core of polymer concrete combination
using hand layup process.
The weight of the product was reduced
from 450 kg (cast iron) to 90 kg. Which
in turn enables a substantial saving in
transportation, installation and handling
cost.

Winner: Hyundai Motor Company
(republic of Korea)
Partnership Network: EELCEE Ab
(Switzerland) HANWHA L&C (Korea)
To conclude, this innovation presents local
reinforcement with continuous fibers (3dTow), load-carrying composite structures
for mass production in automotive industry
as well as compatibility with currently
existing facilities (without large amounts of
investment). The weight reduction is of 20%
to 30% (compared with mere gMT version
of bumper beam). The cost saving is of 10%
to 20% (compared with mere gMT version
of bumper beam). Finally, there is increased
fuel efficiency (lowered CO2 emission)
due to the weight reduction and excellent
recyclability (fully thermoplastics).

Civil Engineering

Using this process, one can make substantial savings in the power that is required during the manufacturing process.
It has zero scrap value, which avoids theft
of the manhole cover and reduces the
probability of accidents. It also has a low
life cycle cost, and is a relatively green
product. It’s an economical solution to
options available.
It was a big challenge to achieve this load
carrying capacity with set weight target
of 100kg. The right combination of glass

Winner: Everlast Composites (India)

fibers, matrix, silica, fillers, and additives
were a key factor in achieving the desired
results. The approximate market potential is of $ 20 billion.

No81 May - June 2013 /

jec composites magazine 37

JEC COMPOSITES MAGAZINE - Issue #81 - May/June 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #81 - May/June 2013