Development of Carbon Fiber-Reinforced Thermoplastics for Mass-Produced Automotive Applications in Japan

Abstract

The application of carbon fiber-reinforced thermoplastics (CFRTPs) for automotive mass production is attracting increasing attention from researchers and engineers in related fields. This article presents recent developments in CFRTPs focusing on the systematic development of lightweight CFRTP applications for automotive mass production. Additionally, a related national project of Japan conducted at the University of Tokyo is also introduced. The basic development demands, the specific requirements of CFRTPs for lightweight applications in automotive mass production, and the current development status and basic scientific outputs are discussed. The development of high-performance CFRTPs (chopped carbon fiber tape-reinforced thermoplastics (CTTs)) and functional CFRTPs (carbon fiber mat-reinforced thermoplastics (CMTs)) is also introduced. The fabrication process control of CTTs is evaluated, which demonstrates the extreme importance of the mechanical performance. The ultralight lattice, toughened structures, and orientation designable components of CMTs provide a flexible multi-material solution for the proposed applications. Moreover, highly efficient carbon fiber recycling technology is discussed, with recycled carbon fibers exhibiting outstanding compatibility with CFRTPs. A cost sensitivity analysis of carbon fiber and CFRTPs is conducted to guarantee the feasibility and affordability of their application. This article also discusses the trends and sustainability of carbon fiber and CFRTPs usage. The importance of the object-oriented optimal development of CFRTPs is emphasized to efficiently exploit their advantages.

Novel Thermoplastic Composites Strengthened with Carbon Fiber-Reinforced Epoxy Composite Waste Rods: Development and Characterization

“…X-ray micro-computed tomography (μCT) is useful for analyzing the fiber volume distribution inside the composites. Several authors have used μCT in composites to determine their fiber orientation distribution [ 20 , 21 , 22 ] and their fiber misalignment [ 23 ]; to analyze void characteristics [ 24 ]; to determine the effect of fiber length, diameter, and orientation [ 25 ]; or to achieve a non-contact characterization of deformation and damage [ 26 ]. Yu et al [ 27 ] studied the variation in the yarn fiber volume fraction induced by the compression between adjacent yarns during the manufacturing process of textile composites.…”

Recent Progress in Carbon Fiber Reinforced Polymers Recycling: A Review of Recycling Methods and Reuse of Carbon Fibers

“…The use phase of composite materials dominates the life cycle energy consumption, especially for those applications that require an energy input, benefitting from these high-performance materials in terms of reduced consumption and emissions due to weight reduction [30,31,32]. Such applications include the aerospace industry or the manufacturing of pressure vessels, with an increasing presence of the automotive industry [33,34,35]. In Figure 1.…”

“…The use phase of composite materials dominates the life cycle energy consumption, especially for those applications that require an energy input, benefitting from these high-performance materials in terms of reduced consumption and emissions due to weight reduction [ 30 , 31 , 32 ]. Such applications include the aerospace industry or the manufacturing of pressure vessels, with an increasing presence of the automotive industry [ 33 , 34 , 35 ]. In such applications, the technical requirements are extremely demanding, which has historically justified the lack of incentives for recycling and recovering the waste generated, focusing on performance almost exclusively.…”

Unconventional Methods of Joining Composites and Metals in the Context of Weight Reduction of Car Bodies

“…Composite materials have their specific properties which is very beneficial in reducing the total weight. The most significant advantage of composite materials with organic matrices is the synergistic combination of the lightweight and conformable formability of the unreinforced resin with the stiffness and strength of the reinforcing fibres [5,28,31]. Among the most well-known and most frequently used composite combinations are composites that combine metals, polymers and ceramics.…”