Composite Technologies Contribution to the Automotive July 2017 JEC Bangkok Lolatte XIA
Composite Technologies Contribution
to the Automotive
July 2017 JEC Bangkok
Lolatte XIA
Where We Are Today
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Agenda
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Introduction
Opportunities for Light Weight Solutions
Innovative Composite Body Solutions
The Key Challenges of Light Weight Solutions
GHG emission Fraction
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Transportation accounts for 15% in all GHG emissions
Land transport is the main cause in all transportation GHG emission
20%
24%
15%
8%
13%
17%
3%
70.9%
15.3%
12.5%
0.6%
0.7%
GHG Emission Fraction in All industry GHG Emission Fraction in all transportation
Source: IAS
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Global vehicle production and marketing break through 108 millions in 2024 by forecast
The fast growing market and high vehicle inventory is causing serious environmental
issues and resources issues
Mill
ion
Veh
icle
s Growth of Vehicles and Consequences
Source: IHS
7/7/2017 6
Compliance to increasingly strict emissions & fuel
economy regulations
+
Compliance to challenging vehicle safety regulations
+
Increasingly challenging cost and margin pressures
The Key Challenge
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Key Market Drivers & Trends
Global Carbon Dioxide standards are becoming increasingly challenging
Region: 2015: 2020:
EU 130g/km 95g/km
Japan 137g/km 105g/km
China 161g/km 117g/km
US 158g/km 121g/km
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Key Market Drivers & Trends
• Vehicle crash safety standards in the world are becoming more and more strict year by year,
such as C-NCAP/E-NCAP/J-NCAP/A-NCAP/IIHS etc…The same trend is that not only
increasing crash speed but also requiring the high strength of vehicle body to protect
passengers.
• The visibility of vehicle is becoming more attractive to customers, so larger windscreen and
sunroof is very popular in current vehicle designs,this means smaller cross section of pillar joint
to address design style but cause a big challenges to vehicle body stiffness.
• Driving more comfortable requires high stiffness vehicle body to reduce vibration.
Agenda
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Introduction
Opportunities for Light Weight Solutions
Innovative Composite Body Solutions
The Key Challenges of Light Weight Solutions
How to Tackle Issued by Increased Vehicles
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5-10g/km of CO2 emission would be saved while reduce 100kg weight per vehicle
The fuel-efficient would be improved 6-8% while reduce 10% weight per vehicle
0.3-0.6 L petrol per 100km would be saved while reduce 100kg weight per vehicle
Light Weight Solutions !!!
Source: IAS
How to Tackle Issued by Increased Vehicles
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Light Weight Design of Vehicle
Battery Technology
Vehicle Reset
Control System
Powertrain System
46%
30%
30%
23%
11%
Light weight design of vehicle accounts for largest proportion among all solutions. It is the
most efficient way for improving emission and saving energy.
Agenda
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Introduction
Opportunities for Light Weight Solutions
Innovative Composite Body Solutions
The Key Challenges of Light Weight Solutions
Miscellaneous Light Weight Design
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Reduce the thickness of metal part of vehicle body while increase metal grade for
keeping equal strength
Optimize structure design
HS steel and HS aluminum in key area of vehicle body
Casting ,Hot Stamped, Rolled and extruded profile structure replace several stamped
parts in key area of vehicle body
Advanced Joining methods for BIW
Composite material for BIW
Challenges of Light Weight Vehicle
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Light Weight is good for environment, energy consumption, driving stability
Traditional light weight solutions bring challenges like high cost and performance loss.
Composite light weight solutions are highly required based on the principles that light
weight solution maintain or improve the performance with limited cost increasement.
Light Weight
Emission
Energy
Durability
Dynamic
Braking
Cost Safety
NVH
The Trend Of Light Weight Solutions
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Hybrid Body Construction
– Steel to aluminium
– Steel to composites
– Aluminium to composites
Why use Composites in Automotive?
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Provide high strength and good
crash worthiness with much lower
weight to:
– Reduce vehicle emissions in
gasoline & diesel vehicles
– Extend electric vehicle range
– Improve vehicle acceleration,
performance & handling
– Compliance to crash
regulations with lower weight
vehicle body in white
Allow for production of large single
components, providing new
options in vehicle design and
functional integration
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L&L Products Biography
Established since 1958, L&L Products
is a privately owned company with
operations in 10 countries, focused
on safety, light-weighting &
acoustic systems for cars, aircraft
and commercial vehicles
L&L Composite Body Solutions
(CBS) technology combines novel
expandable structural adhesive and
composite technology and has been
employed by many OEM’s to enhance
safety, weight & acoustics
performances
L&L Bond structural adhesives
provide outstanding adhesion to all
commonly used substrates, and are
customized to meet all common
processing, performance and
durability requirements
Composite Body Solutions
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Composite Reinforcement
Innovative Composite Bond-Dry Structure Film
CBS®
Composite Body Solutions
Innovative Composite Adhesive- Structure Filling Adhesive
Innovative Composite Bond-RTC
Composite Body Solutions
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Composite Reinforcement
Innovative Composite Bond-Dry Structure Film
CBS®
Composite Body Solutions
Innovative Composite Adhesive- Structure Filling Adhesive
Innovative Composite Bond-RTC
Composite Body Solutions
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Composite Reinforcement
One type of Reinforce technology that is heat activated
and consists of an expandable structural adhesive used
to bond individual sections of the body structure to create
a unified macro-structure.
Usually consist of a formulated expandable structural
Foam material, combined with a engineered carrier
Technologies enable weight to be reduced, while
maintaining or improving vehicle durability, stiffness, and
crashworthiness.
Composite Reinforcement
How Composite Body Solution works
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Heat activated expanding adhesive and an engineered carrier fills cavities and bonds
individual load bearing members to create a unified structure with significantly improved
stiffness and strength attributes.
“Buckling” CBS keeps the stability of the
cross section
High strength expandable
adhesive
Carrier
- Polymer
- Metal
- CF
Without Composite Body Solution With Composite Body Solution
Composite Reinforcement
Solutions
Base Steel Composite Body Solution
Empty Cavity Increase thickness
of steel panel Composite Body Solution
Weight(kg) 2 3.2 2.6
Strength(kN) 6 20.8 25.4
Light Weight Efficiency(kN
/kg) 3 6.5 9.8
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For Strength For Stiffness
Max.Force:25.4kN
Max.Force:20.8kN
Max.Force:6kN
Solutions
Base Steel Composite Body Solution
Empty Cavity Increase thickness of
steel panel Composite Body Solution
Weight(kg) 7.47 9.84 7.89
Stiffness(N/mm) 926 1818 2025
Light Weight Efficiency(N/mm.kg
124 185 257
Composite Reinforcement
How Composite Body Solution works
E-Coat Process
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Attaching CBS part to sheet metal
CBS adhesive expands then
bonds to the body structure
Section (steel) is
e-coated
CBS allows e-coat
flow thru the section
CBS installed in body shop
Composite Reinforcement
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NVH (durability)
NVH (stiffness)
Typical application areas:
Pillars
Closures
Roof
Rocker
Cowl Bay
Under body
NVH solutions for optimizing your BIW:
Global stiffness
Local stiffness
Durability
Torsion/bending mode
Torsion/bending stiffness
Improve NVH and durability for lightweight body design
Composite Reinforcement
Typical Application-Why Composite Body Solution required
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BIW (With Battery) Current Status: Tosional Frequency:40.19Hz (Target 40)
Bending Frequency:41.2Hz (Target 40)
Requirement: 4kg weight reduction
Steel Solution: Investigate Sensitive area:
1.Add steel brackets in D ring joint ( +1.2kg)
2.Reduce thickness of steel parts ( - 4.2kg)
Effect: Weight Reduction: 3kg
Tosional Frequency: 37.9Hz
Bending Frequency: 39.1Hz
ISSUES: Achieved 3kg weight reduction but performance
loss is unacceptable
Add steel bracket in D ring is a big challenge for
assembly process
30+ spot welds added will increase much cycle
time
Composite Reinforcement
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CBS Solution: Investigate Sensitive area:
1.Add CBS in B/C/D Ring ( +2.8kg)
2.Reduce thickness of steel parts ( - 7.0kg)
WINNER! Achieved 4kg weight reduction While maintain
performance
Easy Assembly process,clips or push-pins for
attachment
30+ spot welds saved compared with steel solution
Cycle time saved compared with spot weld process
Effect: Weight Reduction: 4.2kg
Tosional Frequency: 40.19Hz
Bending Frequency: 41.10Hz
Composite Reinforcement
Typical Application-Why Composite Body Solution required
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L&L Solution
1.4 kg/vehicle mass savings
0.68 kg/part 1.38 kg/part
Sub frames & Cradle Mounts
• Adhesive spreads the loads for improved
durability
• Structural insert bonds to the nut and the
four sides of the section
• Improve local stiffness
• Mass reduction
• Steel solution traditionally consist of thick
steel components due to the high stress
• Adhesive eliminates the welding heat
affected zone
Composite Reinforcement
Typical Application-Why Composite Body Solution required
Improve structure safety for lightweight body design
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Front crash
Side impact
Rear crash
Roof crash
Small overlap front
Typical Safety Regulations:
FMVSS
IIHS
ECE
NCAP
Typical application areas:
Pillars
Rails
Floor
Rocker
Typical Safety Ratings:
Composite Reinforcement
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Current Status: A Pillar broken during front offset impact
Requirement: Need improve structure strength of A pillar to meet
crash target
Steel Solution:
1. Hot stamped Reinforcement in A pillar ( +1.3kg)
2.Insert Structural Foam on steel part as connection
due to spot weld is unavailable.
Effect: 1.CAE shows unacceptable performance with Steel insert
2.Proposal failed ,no opportunity to test in real vehicle.
ISSUES: Hot stamped steel still cannot solve big deformation
issue in A pillar.
Weight is too heavy
Need 4 months product development cycle.
Tool cost is too expensive for this hot stamped part.
Composite Reinforcement
Typical Application-Why Composite Body Solution required
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CBS Solution: 1. CBS Reinforcement in A pillar ( +0.9kg).
Effect: 1.CAE show acceptable performance with CBS
2.Proposal Succeeded, crash test in real vehicle
show acceptable result.
Winner: CBS solved big deformation issue in A pillar.
0.8kg/vehicle mass savings
Only 2 months product development cycle.
Injection Tool cost is much cheaper than hot stamped
part.
Composite Reinforcement
Typical Application-Why Composite Body Solution required
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Evolution of Composite reinforcement
Composite Reinforcement
Steel Solution:1.087kg
1st Gen CBS:0.47kg
PA66GF30 Carrier
2nd Gen CBS:0.28kg
CFRP Carrier
Require Improve the section force of B
pillar to 40 kN
From Steel reinforcement to 2nd
Gen CBS ,mass added from 1.087kg
to 0.28kg to achieve same target
Composite Body Solutions
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Composite Reinforcement
Innovative Composite Adhesive- Structure Filling Adhesive
Innovative Composite Bond-Dry Structure Film
CBS®
Composite Body Solutions
Innovative Composite Bond-RTC
Structure Filling Adhesive
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The Structure Filling Adhesive is formulated
to provide superior ductility and deliver a
high performance structural bond. With
expansion of 200%~300%, has the unique
ability to provide structural bonding while
bridging a typical and varying design gaps.
Key Product Attributes
• Gap Jumping
• Fracture Toughened Technology
• Structural Reinforcement
• Dissimilar Material Joining
• Increased Durability & Stiffness
Structure Filling Adhesive
Typical application-Structure Filling Adhesive
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Roof panel
Roof Frame
Body Side
Panel
Light weight Adhesive:
1.Bonding roof frame and roof rail panel
2.Absorb big tolerance between two assembly-sunroof and body side
3.Gap Jumping -3mm thickness in green state and 6mm after cured
4. Material made as tape,stable dimension,no need equipment for
operation
5. Increased 1.2Hz torsional mode with 0.1kg mass added. Compared to
steel proposal light weight ~1kg
Roof Rail
Panel
Laser
Welding
Structure Filling Adhesive
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Tailgate: 1st Torsional mode Target: 28Hz
Baseline: 1st Torsional mode :23.27Hz
Failed
Steel Solution: 1st Torsional mode:24.95Hz
Failed
Add mass:1.2kg
Thicker steel reinforcement
Structure Filling Adhesive
Solution: 1st Torsional mode:28.97Hz
Winner!
Add mass:0.05kg
Typical application-Structure Filling Adhesive
Structure Filling Adhesive
Composite Body Solutions
07/07/2017 36
Composite Reinforcement
Innovative Composite Adhesive- Structure Filling Adhesive
Innovative Composite Bond-Dry Structure Film
CBS®
Composite Body Solutions
Innovative Composite Bond-RTC
• As an evolutionary development from structural foams
and tapes, L&L Bond dry structural adhesives cure in
the heat of the e-coat oven, bonding a wide variety of
substrates.
• As opposed to conventional structural adhesives, which
are liquids or pastes before they are cured, L&L Bond
dry structural adhesives are solid and dry-to-touch at
room temperature.
• High Strength and stable dimension with varies thick
from 0.3 to 1mm.
• With an option of fleece material integrated to increase
strength
Dry Structural Adhesive
Dry Structural Film
07/07/2017 37
Steel
e- H2O
Ex.: Bonded Carbon-Steel assembly: Galvanic corrosion insulation
Localized contact possibility due to part geometry or positioning: Electron exchange still possible. St
and
ard
pu
mp
able
ad
hes
ive
Stru
ctu
ral a
dh
esiv
e
film
wit
h g
lass
fle
ece
Steel
Carbon H2O
No contact due to part separation by physical glass insulation: No electron exchange possible.
Risk of part corrosion
No Part corrosion
Why need dry structural adhesive
Dry Structural Film
07/07/2017 38
Typical applications
Rear Mirror
Bonding
Spacer while fastening bolts
Trunk Hinge
Bonding
Sealing
B Pillar
Bonding
Spacer while compress CFRP
Front Lamp
Bonding
Al-Al
Front Lamp
Bonding
Al-Al
Dry Structural Film
07/07/2017 39
Composite Body Solutions
07/07/2017 40
Composite Reinforcement
Innovative Composite Adhesive- Structure Filling Adhesive
Innovative Composite Bond-Dry Structure Film
CBS®
Composite Body Solutions
Innovative Composite Bond-RTC
• Automotive interior applications offer a
number of opportunities to bond composites
to other substrates:
• Dashboard retainer to composite CCB
• Dashboard retainer to composite topper pad
• Knee bolsters & glove box door assemblies
• HVAC unit
• Door panel assembly
Interiors Bonding-RTC
RTC
07/07/2017 41
Exteriors Bonding-RTC
RTC
07/07/2017 42
• Applications include fenders, tailgates, boot lids & closures
Summary
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Where you can find the successful composite body solutions…
……
Thank you for your attention !
• Questions ?
• Suggestions ?
07/07/2017 44