Advanced Thermosetting Resin Matrix Technology for Next Generation High Volume Manufacture of Automotive Composite Structures

Abstract

Composite materials have gained the attention of the automotive industry to substantially reduce vehicle weight, reduce CO 2 emissions and improve the fuel economy of next generation vehicles. Thermosetting matrix technology combined with glass or carbon fiber reinforcements are well suited for structural applications where mostly steel and aluminum are used today. However, the lack of fast production techniques and fast reacting matrix technologies have limited composites use to low volume production models. A new generation of epoxy resin systems has been developed that allows the rapid processing of structural composites for medium to high volume models. These advanced formulations maintain the excellent properties of traditional epoxy-based composites, yet the tested systems can process in a matter of minutes using modern manufacturing technologies such as the high pressure resin transfer molding (HP-RTM) process. The advanced formulations are unique in that they provide a long enough injection window for a robust impregnation of the reinforcing fibers while still enabling an extremely short cure cycle. The results from this development show that structural composite components can be produced economically and in high volume using today's innovative resin and process technology.

Carbon fiber-reinforced composites using an epoxy resin matrix modified with reactive liquid rubber and silica nanoparticles

“…The diglycidylether of bisphenol A (DGEBA) is the most commonly used epoxy resin in automotive industry. Very important is low viscosity of the resin as the preferred manufacturing methods for automotive parts currently are injection or infusion processes -which enable short cycle times [3].…”

“…Of course automotive manufacturing has its own rules, one is a very short part production cycle, like the stamping of metal parts. Thus composites manufacturing technologies and the materials used have to be adapted accordingly [3].…”

The Effect of Gelcoat and Lamination Plan on Mechanical Properties of the Final Product in RTM Method

“…RTM prosesi beş temel aşama içermektedir, bunlar; 1) Takviye Yerleştirme, 2) Kalıp Enjeksiyonu, 3) Polimerizasyon, 4) Kürleme, 5) Soğutma ve Son İşlemler'dir (Hillermeier et al 2013). Şematik gösterim Şekil 2'de gösterilmiştir (Friedrich et al 2011).…”

Comparative Life Cycle Assessment of Safety Shoes Toe Caps Manufacturing Processes

“…Once the desired thickness is reached, a compression molding process is performed. This process, irrespective of the reinforcement nature, is mostly manual and the time necessary to cure the thermoset matrix varies from 5 to 30 minutes, these values are sensibly higher than those of metallic toe caps production [3]. Plastic toe caps are usually produced by exploiting thermoplastic polymers that guarantee automated production and low processing time.…”