JEC COMPOSITES MAGAZINE - Issue #121 - May 2018 - 54

LAND TRANSPORTATION awards

PUBLIC TRANSPORTATION

Design and Fabrication of an Integrated Monocoque Composite 40ft Plug-in Electric Transit Bus
Winner: TPI Composites (USA)
Partner: Proterra (USA)
TPI Composites has designed and produced an all-composite monocoque plug-in electric bus body with Proterra.
Engineers at TPI and Proterra collaborated in the design and development of a unique structural composite bus
body. The Proterra "Catalyst" is a unique design which incorporates fiberglass and carbon fiber non-crimp fabrics and a modified vinyl-ester in a
vacuum resin infusion process. Design innovations include the use of integrally infused carbon pultrusions to carry the passenger and battery load,
limiting deflections between the wheelbase. A unique approach to direct front-end impact through the vehicle floor provides a level of protection
not achieved in conventional metallic design or SMC bonnets. The Catalyst design creates a distinctive body style made possible by composite
molding. Mass reduction of over 40% compared to the steel baseline enables unprecedented range. Unitary tooling and molding of the bus structure creates a distinct and unique body styling that is not possible with metal fabrication. The bus structure includes extensive use of sandwich
construction unique to composite fabrication and improves: structural efficiency, noise, and thermal insulation. Innovative fastening technologies
include threaded fittings, tapping plates, through-bolted solutions and combine to provide a system that flows smoothly through vehicle assembly.
The additional value of a corrosion resistant vehicle structure enables a projection of more than 20 years of service where conventional steel systems
project to 7 to 11 years of service life. The all-composite Proterra bus enables electrification of public transportation, and is leading to the expanded
use of composite systems and sub-systems in all forms of transportation, including bus, truck and automotive applications.

HEAVY TRUCKS

Self-molding, High Heat Composite Insulation System
Winner: Saprex (USA)
The project consists of a self-molding, PPS, thermoplastic composite insulation system for large bore diesel engine
exhaust systems tests.
Saprex has developed a self-molding glass and PPS composite systems that self-molds arounds exhaust tube of large bore
diesel engine vehicles. Using braided insulation, an innovative knit cover material and a water based, PPS, thermoplastic
composite resin that was developed by Saertex, it has been made possible to produce a rigid insulation system on almost any geometrical configuration of tubing. This allows the easy installation, infinite changes in tubing geometry and long-service life. The innovation has been adopted by
PACCAR, Daimler and Navistar. Instead of having to produce dies to make metal stamped and welded insulation covers, Saprex provides a totally
flexible system that can be applied to any geometry of pipe that completely removes the need for dies and molds. This innovation is unique in the
composites world, since composite materials are used to replace metal products that make dies and molds necessary. The water based, environmentally friendly PPS composite resin can be brushed, sprayed or used as a dip to deliver a matrix into a composite system. PPS is easily recoverable from
waste product and an environmentally friendly water solution remains

SUSTAINABILITY

Light-weight Automotive Interior Parts with Natural Fiber Reinforcement
Winner Bcomp (Switzerland)
Partner: Persico (Italy)
The innovation consists of forming, back injection & punching of automotive interior parts with natural fiber reinforcement in one step, showing full
readiness for large-scale implementation in existing production lines.
Up to 40% lighter automotive interior parts at competitive pricing, are now available at industrial scale, with a highly efficient one-step back-injection, that compression molds powerRibs flax fiber reinforcement rib structure together with a base non-woven material of choice (typically NFPP
fleeces), as well as decorative layers on the A-side in the same step. The collaboration presented here brings this process to full industrialization
readiness. It shows that the unique reinforcement can be integrated in a one-step forming process, which includes back injection of attachment
features and punching. With the innovative employment of a soft silicone on the B-side on the compression molding tool, the full stiffening potential of the powerRibs preform is reached and maintained. Thanks to this innovation, it is shown how this highly engineered preform can be
seamlessly integrated in large-scale, highly efficient, top notch production lines, in order to produce plug and play lightweight and strong interiors
for tomorrow's automobiles.

jec composites magazine / N°121 May - June 2018

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #121 - May 2018