The Winners of 2015 CCE-JEC Innovation Award——New Applications
原文：http://www.chinacompositesexpo.com/en/news.php?news_id=19991. Product Name: Continuous Carbon Fiber Reinforced Polyphenylene Sulfide(CF/PPS) Composite Front Bumper
Source：Organizing Committee of CCE 2015-9-10
Exhibitor: Ningbo Institute of Material Technology & Engineering, Chinese Academy of Sciences
Partner: Chery Automobile Co., Ltd.
Lightweight structure technology for the body of cars is one of the most effective ways for energy saving and improved driving performance. The front bumper is a typical structure part for the application of composites in vehicle. The product of continuous carbon fiber reinforced polyphenylene sulfide composite front bumper can be used for cars with monocoque body or body chassis frame construction. The manufacturing process can also be extended to fabricate other types of automotive panels and be applied in other fields.
Production place: Ningbo City, Zhejiang Province, China.
Technical Features: High performance continuous carbon fiber reinforced thermoplastic composites have been widely used in aerospace, navigation, national defense, automotive, civil engineering and other fields due to their excellent properties. However, the manufacturing efficiency of continuous fiber composites has always been a difficult problem. This product has shown that the low-cost and automatic manufacturing technology of continuous fiber reinforced thermoplastic composites. It contains three processes: hot-melt impregnation, continuous laminate preparation and hot stamping. The production efficiency can reach 8 parts / hour, which satisfies the demand of mass-production for vehicle structure parts with high mechanical properties in automotive industry.
1. The precision of specification after forming:
- Deviation of product size <5%;
- Inner and outer panels meet the demand of design size precision;
- Product meets the demand of assembly size precision.
2. Composite front bumper collision test compared to the metallic front bumper:
Specific energy absorption(SEA)/（J·kg-1）
Increase percentage of SEA/%
Metallic front bumper and Metallic energy absorption box
CF/PPS front bumper and metallic energy absorption box
3. Mechanical properties of continuous carbon fiber reinforced polyphenylene sulfide (CF/PPS) composite
Tensile strength: 1080.34MPa Tensile modulus: 80.29 GPa
Flexural strength: 982.28 MPa Flexural modulus: 62.99 GPa
Interlaminar strength: 50.57MPa Impact strength: 54.11kJ/m2
With the challenges of safety, energy saving and environmental protection in the global automotive industry, electric car technologies are a strategic part dramatically reducing the energy and environmental burdens. Thermoplastic composite constructions open up great potential in electric cars for weight reduction, which have been growing steadily, especially in automotive and aerospace applications, due to their recyclability, improved impact resistance and rapid processing ability. At present, discontinuous fiber-reinforced thermoplastic composites have been widely used to manufacture secondary structure parts in the automotive industry, while primary structure parts have an increasing demand for continuous fiber-reinforced thermoplastic composites to meet the requirements for high mechanical properties. The continuous carbon fiber reinforced polyphenylene sulfide composite front bumper can be fabricated in a mass production rate, which overcomes limitations of manufacturing and cost associated with traditional continuous fiber-reinforced composites. It shows great potential in industrial applications and will further promote the development of new markets for composite in the range of tens of billions of RMB.
2. Product Name: Rocket Engine Bracket of Carbon Fibre Composite
Exhibitor: Harbin FRP Institute
Carrying assistant flight engines of all angles. Production place: Harbin, china.
The carbon fiber bracket developed for Shanghai Space Dynamic Institute was made with carbon fiber instead of metal for the first time in China. Its weight decreases by a third compared with the metal bracket. The technologies are different. For the carbon fiber bracket, in-mold technology is adopted to highly increase the product performance. The problem of the strength and stiffness design and check was solved through analyzing and optimizing the complex multi-opening structure accurately in the finite-element method. There are no reports of similar products in China.
The product created great economic efficiency and market prospect. The invention of the product had vast importance to the domestic space flight area. The successful development of the product obtained the recognition of the users. Later we continued researching and developing more types of composite bracket. The brackets carrying all the small engines of Chang’e-3 successfully were made by us. These years’ developing experiences will offer the powerful support for using the composite bracket instead of the metal bracket in future.
3. Product Name: Fast-Erecting Modular All-Composite Heavy-Duty Emergency Bridge
Exhibitor: Wuhan University of Technology; China Harzone Industry Corp., Ltd.
The emergency bridge can be well applied over waters, with a maximum load of 40 tons. It is composed of different lightweight modulars, easy for transportation and installation. By doing so, the overall weight is reduced by 20%, compared with traditional steel bridges. Production place: Wuhan, Hubei province, China.
Traditional emergency bridges are made of steel and aluminum alloy, connected by welding or bolts. But they heavy weight can no longer satisfy markets requirement for lightweight. As a better alternative, composites can greatly reduce bridge weight, shortens installation time while fully fulfill the requirement for 40 tons loading capability.
The heavy-duty bridge is 8m in length, composed of 12 modulars or 6 units. Each modular spans 4 meters. The bridge is wholly composites-made, with maximum load capacity of 40 tons and featured by:
1) Horizontally, units are connected with each other by self-locking structure.
2) Each unit is produced using VA-RTM process.
3) Vertically, modulars are connected with each other by a connector, made with uni-directional carbon fiber and metal ear. Each ear can bear a maximum loads of 17 tons while each unit has 5 metal ears, which makes it can bear 85 tons loading.
Composites fast-erecting emergency bridge is designed by Wuhan University of Technology and China Harzone Industry Corp., Ltd., and produced by the former. Its mechanical properties are tested them together as follows:
1) Single Modular Weight <140Kg;
2) Span 7.5m, the center deflection <90mm under 42 tons static load;
3) It has passed 43 tons wheel tests for 500 times and 40 tons track tests for 200 times, with no failure.
Its performance has reached the requirements of emergency bridge.
Regarding its extraordinary performance, composites emergency bridges have been studied and developed for many year in developed countries. China is a country with regular natural disasters, where composites emergency bridges are expected to have huge market potential. Our product may be well applied in Defense Industry, Disaster Relief, Engineering Construction, etc.
4. Product Name: High Performance Low Loss And Overall Forming Hollow Structure Radome Body
Exhibitor: Beijing Sinoma Composite Auto Parts Co., Ltd.
Partner: Hollow Composites Division of Sinoma Science and Technology Co., Ltd.
High performance low loss and overall forming hollow structure radome body could effectively increase wave performance of antenna system, this radome is mainly used in aerospace, communications vehicles, weather radar and mobile base stations, and other fields. Production place: Beijing and Nanjing.
Overall forming hollow radome body is a new type of wave-transparent concept, with many performances better than traditional honeycomb and foam structure, which has high strength, delamination resistance, high pressure resistance, leakage resistance, corrosion resistance, anti-aging, easy forming, wave-transparent well, low cost, etc., especially for the design of electromagnetic window structure used in radome and beautify cover. Existing antenna protection device gradually develops from radome plus beautification hood to integration radome, It put forward higher requirements in wave-transparent, strength, aging performance and so on, But currently the electric performance is poor (dielectric constant is 3.8-4.2, loss tangent value is greater than 0.009), The overall molding hollow of the radome body wave-transparent performance better (dielectric constant is 1.8-2.5, loss tangent value is less than 0.007).
During the developing of the overall forming hollow antenna radome process, we developed a kind of dedicated presoak cloth, achieve the hood body continuous molding technology, and carry out the study of performance and structural strength design and evaluation.
, Tensile strength≥100MPa, Flexural Strength≥50MPa, Compression strength≥2MPa, Surface tensile strength≥3MPa, Barcol hardness≥40, Impact toughness 355KJ/m2
Dielectric constant is 1.6~2.5, the loss tangent value≤0.007, the average wave-transparent within wave frequencies rate of in 2 ~ 18 GHZ is ≥ 85%.
At present, we has carried out the development of the aviation and aerospace broadband radome of the overall molding hollow radome body, product performance and structural strength has significantly increased compared with cellular or foam structure; In addition, with the development of 4G/5G technology, there comes a appeal to upgrade the low loss, broadband radome body. Its market demand is expected to reach 400,000 pieces per year, and has good market application prospect.
5. Product Name: Composite Jumbo Tube
Exhibitor: Sinoma Science & Technology (Suzhou) Co., Ltd.
This product is mainly used for storage and transportation of compressed natural gas. Production place: Chengdu, Sichuan Province, China.
Sinoma Large-diameter composite tube unit is featured by lower cost, advanced and integrated technology, shorter development cycle, compared with similar products. “Sinoma” is a manufacturer engaged in rapid and large-scale production and has optimized comprehensive performance.
The tube unit consists of carbon fiber composites body, electrochemical corrosion-resistance coating, insulation structure, fatigue and cracking resistance structure, which can satisfy storage and transportation requirement of gas industry. The product meets international ISO 11515 standard.
Volume-weight ratio of large-diameter composite tube is at least 30% higher than traditional steel tube, allowing it of a same weight to transport more gases.
As a storage and transportation method, large-diameter composite tube provides a new solution for natural gas industry, contributing to increasing transportation efficiency and decreasing cost, thus having a good market prospect.
This product contains four key technologies:
- high strength and light weight composite layer design
- fatigue and cracking resistant structure for composite layer
- electrochemical resistant corrosion coating and insulation structure
- multiple tubes assembling and fixing technology
The product has drawn attentions from clients home and abroad and won quite a new oversea orders. Due to its lightweight and large volume, the market potential is huge.
6. Product Name: The Bus with Module Lightweight and High-Performance Composite
Exhibitor: Changzhou Hongfa Zongheng Advanced Material Technology Co., Ltd.
Partner: Changzhou Greenauto Union Co., Ltd.; Beijing University of Aeronautics and Astronautics
The product has excellent properties, such as safe, low noise, thermal insulation and heat insulation etc. It can save energy, reduce environmental pollution, ensure safety and a series of efficiency for the bus’s weight and rolling resistance is reduced. The assembly units are produced in the R&D workshop of PGTEX.
Technical Features: Technology:
(a)The product adopts a body structure of the module lightweight composite, different from the traditional structure which bus body and chassis were welded joint for the integration, and greatly reduces the weight of the bus and also give its higher mechanical properties.
(b) The modular of the products includes bus body and bus frame structure composite material of modularization, we can make different length, type of buses according to users’ requirements.
(c) The product adopts bolts for all connection area. The nuts are a kind of imported special locknuts, bolt connection is detachable, while guarantee the connection strength can meet the containerization transport. Both domestic users and foreign users are convenient and quick to buy the products, and can assemble the buses follow the instructions, and at the same time easy to maintenance and replacement during the using.
The bus body adopts thermoplastic and thermosetting composite sandwich structure. Inner and outer panel is fiber reinforced thermoplastic or thermosetting composites. The core material uses thermoplastics. Through designing the inner and outer panel layers, we not only ensure the bus body’s strength, stiffness and impact properties, but also sharply reduce its weight.
The body adopts high voltage RTM manufacturing process. Production system includes preform process, pressing process and correction process. Compared to traditional RTM process, it reduces the resin injection time, improves the quality of impregnation, and shortens the molding cycle. The product has the following characteristics: (1) high production efficiency; (2) highly automated process;(3) shorter processing cycle;(4) No need to use auxiliary materials both in preprocessing and injection process;(5) good surface quality and low porosity.
The mainly power source of the product is batteries, hardly discharge harmful gas. In terms of energy conversion, electric energy is cleaner than burning fuel directly. Through battery charging, improving energy efficiency and reducing the degree of dependence on oil, and also improving the nation's energy and economic security
Automotive industry is the pillar industry of national economy in our country, which has achieved rapid development in recent years. The rapid development of the automotive industry led to the rapid increase of car ownership, but also to the society brings the three major problems: lack of energy, environmental pollution, safety problems. Automotive energy saving, environmental protection, safety is not only the development orientation of international automotive technology, is also the requirement of China's auto industry policy. Reducing fuel consumption and pollution to the environment has become key problems of the auto industry development and the social sustainable development which need to be resolved. Automotive lightweight, is one of the most effective way to save energy, is also the important goal of the international advanced bus makers pursues