General plastic in the proportion of 0.9-1.6, glass fiber reinforced composite material in the proportion of 2.0, while the A3 steel is 7.6, brass 8.4, aluminum 2.7. Therefore, although the strength is not as good as carbon fiber, metal material, but from the proportion of the weight of the plastic light the best, can be described as the preferred vehicle lightweight material. The use of plastic can reduce the weight of parts of about 40% of the car's power, comfort and safety can be improved. The future of its innovative applications may subvert the traditional car.
Three ways to lose weight
The newly revised National Standard for Fuel Consumption Limits will be implemented on January 1, 2016. The annual fuel consumption will be set to a value of up to 5.0 liters per 100 passenger car Km. Increasingly stringent fuel regulations, prompting all car manufacturers to spare no effort to develop automotive lightweight technology.
Car lightweight is not simply weight loss, need to take into account both product features, cost and quality elements. In terms of "plastic and steel", there are three main ways: to optimize the quality of materials; modular and integrated; structural optimization design.
Material performance is the most critical high performance
Foreign car brands are now large-scale use of high-performance engineering plastics and plastic composite materials. Future car doors, roofs, seat parts, wheels and car peripheral structural parts, and even the body are likely to switch to engineering plastics. The use of fiber reinforced composite plastic material produced by the body compared with the steel body, can be reduced by 35%; if the use of carbon fiber reinforced composite materials, you can reduce weight more than 60%.
Honeycomb sandwich structure has been widely used in automotive interiors, including trunk floor, roof liner and rear sash. The new Mercedes smartfortwo uses BASF ElastoflexE polyurethane foam in the honeycomb sandwich structure roof, which consists of honeycomb sandwich and fiberglass liner, which is about 30% lower than the average roof, but still maintains good strength and resistance Bending stiffness.
Bond-Laminates, a polypropylene-based continuous fiber-reinforced composite Tepexdynalite, also offers significant opportunities for lightweight automotive production, especially in large components with high strength requirements, such as backup Box floor, electric vehicle extended range device shell and seat components.
Modular production has become a trend
In the modular, integrated, the plastic has a very obvious advantage. At present, many components and systems, such as side door systems, instrument table systems, engine systems, etc. have been achieved modular production. Full plastic frame, local metal insert Enhanced integrated module front-end structure can achieve 30% weight loss, and can greatly reduce the number of parts to enhance the efficiency of assembly. It is reported that BMW, Mercedes-Benz, GM, Renault, logo and many other European and American enterprises have matured front-end module, door module technology.
Structural optimization design can not be ignored
Structural optimization design is also an important way to reduce the weight, to meet the requirements of the process under the premise of structural shape and size design. For example, the development of thin-walled bumper, conventional design for the 3.0MM wall thickness, the use of ordinary PP talc powder material, single weight 4-5kg. According to Geely Automobile Research Institute, general manager of Xiong Fei, Geely 2.5mm wall thickness design, high rigidity PP material, a single weight loss of 10% -15%. At the same time, he pointed out that to achieve light weight can not be confined to the material, only the depot of the material department involved in vehicle design, in order to effectively promote the new materials, new technology applications. In other words, the performance and design is the fundamental car, the material should be developed around these two points, on this basis to achieve lightweight, and then get better fuel efficiency and vehicle performance properties.
Innovative technology to escort
Long glass fiber reinforced composite materials, carbon fiber reinforced composite materials, and modified low-density, micro-foam, thin-walled plastic materials is the hot research of automotive materials. The development and application of these materials is inseparable from the support of innovative processes.
Long fiber injection, is a lightweight structure of an innovative process. Arbug's long fiber is directly injected into the molten plastic directly through the servo motor-driven feed device to cut the continuous fibers into lengths of 15-50mm. The two-stage screw ensures that the molten plastic particles While feeding fiber, to ensure uniform mixing, and truly achieve the purpose of increasing strength. Take the long-fiber direct injection of automotive airbag shell as an example, the use of 16mm glass fiber direct injection, 50% of the glass fiber length can be greater than 2mm, much better than long fiber pellet injection.
Engels Mold Manufacturing (China) Co., Ltd. exhibited its new FLEXflow servo drive valve gate system at CHINAPLAS2015. It is especially suitable for large plastic parts, high quality optical parts, high performance engineering materials and narrow process windows. Injection molding applications. In terms of cost savings, can reduce the clamping force of about 20%, reduce the weight of plastic parts up to 5%.
MuCell micro-foam injection molding technology in the use of automotive manufacturing increasingly popular. There are media reports, Land Rover plans to 2017 in all models are used MuCell technology. Microcellular foam refers to the thermoplastic material as the matrix, through a special processing technology, so that the middle layer of the product size from ten to tens of microns closed pores. The MuCell process is particularly advantageous in terms of weight reduction and can reduce the weight by up to 10% under basic warranty strength. The cycle is reduced by 50% and the average cost is reduced by 16% -20%. As early as 2000, Trexel first realized the commercial application with this technology, based on its cooperation with MIT. Many of the world's leading equipment and raw material manufacturers, including Arbug, Demag, Engel, Husky, Dupont, have purchased the patent right to use this technology. To achieve the goal of lightweight, the future MuCell will continue to be applied to the industry technology.
The CHINAPLAS2016 International Rubber & Plastic Exhibition, which brings together the world's state-of-the-art plastics technology, will be held at the Shanghai New International Expo Center (Pudong) from April 25 to 20, 2016. The exhibition area is more than 240,000 square meters and gather more than 3,200 Exhibitors and a number of national pavilions. At present, well-known exhibitors who have booked booths include BASF, BirlaCarbon, Celanese, ExxonMobil, Clariant, Mitsui Chemicals, DSM, LG Chemical, Evonik, Phi Phi, Polyplastics, SK Integrated Chemicals, Su Granville, Teijin, Stone Group, Sumitomo, Demag, Engel, Fang Li, Hashis, Haasi Gao, Engels, Maast Mold, Ningbo Shuangma, Nordson, Of the secret, Liu Road, Yuntianhua, Long and so on.
The exhibition is expected to have more than 140,000 professional visitors from more than 150 countries / regions to visit the show business and procurement. Has attracted many international well-known vehicle and auto parts enterprises to participate in the event, including BYD, Dongfeng Nissan, FAW-Volkswagen, Fusi, Beiqi, General Motors, Mitsubishi Motors, Shanghai Automotive, four Weier Marui, Zhengzhou Yutong, Yanfeng car, Weisi Da, Hyde world cable, Showa auto parts, Tian Tian auto parts and so on. Is about to usher in the "30-year-old" golden age of this show, will show a vibrant spectacular, to meet a more brilliant future.
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