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Oral Poster Presentation

Development of CFRP - hybrid foam composites for improved light-weight design of electric vehicles

Wednesday (07.10.2020)
18:40 - 18:43

The use of electric driven cars has been increasing significantly in the last few years. However, several challenges have still to be addressed as e.g. increasing battery capacity and range of the car, ensuring battery safety in crash events providing comfort in all kinds of passenger vehicles in a wide range of operating conditions without consuming a significant amount of energy from the battery. The European project QUIET aims at developing an improved and energy efficient electric vehicle with increased driving range under real-world driving conditions. This is achieved by exploiting the synergies of a technology portfolio in several areas, among those e.g. lightweight materials with enhanced thermal insulation properties, and optimised vehicle energy management. The developed technologies are integrated and qualified in a Honda B-segment electric vehicle validator. One of the project’s targets is the development of a light-weight side door with improved thermal insulation and keeping the strength of the baseline steel construction besides good crashworthiness. The technological concept comprises a door structure with face sheets made of CRFP composites combined with two internal crash beams. Latter were also produced using CRFP. For improved energy absorbing performance under bending loads the beams were filled with APM aluminium foam rods. Aluminium foam granules of 4 mm were coated with polyamide and cured in the shapes of cylindrical rods. Subsequently, the APM foam rods can be inserted and bonded into the premanufactured CFRP tubes. In the presentation the production and properties of the foam cores and the overall demonstrator door will be illustrated.

Joachim Baumeister
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Additional Authors:
  • Dr. Joerg Weise
    Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Bremen (DE)
  • Tamas Turcsan
    eCon Engineering Ltd.