Project Lightweight Door A new concept for a lightweight door

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1 Project Lightweight Door A new concept for a lightweight door

2 Index: A lightweight functional door demonstrator 1 Project partners 3 Project system approach 5 Materials & Technologies 7 Design / Engineering consultancy 20 Door trim panel demonstrator 21 Integration of functionalities 23 Door demonstrator validation 25

3 steel wire and coating tailored blanks aluminium extrusions steel research design support durable lightweight vehicle systems advanced materials sound systems sealing and bonding materials interior trim Project partners

4 A lightweight functional door demonstrator A two-year ( ) collaboration project of 10 partners with the following objectives: Developing new materials and technologies for weight reduction and integration of functionalities Integrating and validating the developed technologies in a passenger car door demonstrator Focusing on materials and technologies for high-volume production Acquiring knowledge to be used also in other applications within and beyond the automotive industry 1

5 A system-level development approach has been applied taking into account the following considerations: Existing functionalities: must be kept at least at the same level as state-of-the-art doors Assembly process: no negative impact of new concepts on assembly time Production process: new materials must be produced at high-volume rate Cost: new materials and technologies with comparable cost as existing ones Recycling: new materials and technologies must meet the prevailing recycling requirements The project objectives have been realised, making good use of the synergies of the specialist knowledge and expertise of the project partners in the field of Materials, Design, Joining technologies, Integration, and Validation. 2

6 Project partners ArcelorMittal is world leader in laser welding of steel sheets of different thicknesses and Tailored Blanks strengths for automotive applications with the aim of increasing the safety of passengers and at the same time reducing vehicle weight. (www.arcelormittal.com) Bekaert D&M PSS is a global technological leader in its two core competences: advanced metal transformation and advanced materials and coatings, and a market leader in drawn wire products and applications. (www.bekaert.com) is an innovative worldwide supplier of advanced audio systems to the automotive industry. This includes the development of loudspeakers, multi-channel DSP amplifiers, and also the integration and acoustic tuning of audio systems. (www.dm-holdings.com) Flanders DRIVE is the Flemish initiative that develops competences for the automotive industry with a focus on innovation in products and processes. Since 2008, it has evolved from a knowledge network and test platform into a fully fledged and internationally recognised research institute. (www.flandersdrive.be) 3

7 hegge ID Nitto Europe OCAS Recticel is the expert in design and engineering, transforming ideas and concepts into visual and concrete developments. (www.hegge-id.com) combines its expertise in production techniques, such as polymerisation, coating, foaming and finishing, with extensive know-how in damping, sealing and reinforcement for innovative applications in the automotive industry. (www.nittoeurope.com) develops new steel grades and coatings for the ArcelorMittal group and offers its clients innovative steel and metal-based solutions. (www.ocas.be) is the expert in polyurethane and in developing automotive interior parts in this versatile material. (www.recticel.be) Sapa RC Profiles is specialist in co-development and production of profiles, fabrication and joining technologies in aluminium, including friction stir welding, right through to delivering a completed product. (www.sapagroup.com) Umicore is a material technology group with expertise, among others, in new developments in nanotechnology and Advanced Materials (www.umicore.com) 4

8 Project system approach System validation System functionalities & requirements analysis System architecture & packaging Components integration Component material & design optimisation 5 Components validation

9 Taking into account the end customer requirements has reduced the gap between technology push and market pull Benchmarking to identify specs & requirements Innovative design to integrate new technologies & reduce weight Validation test to prove the new technologies 6

10 Materials & Technologies Steel-cord reinforced PU Concepts Dual phase steel (TS 500 DP) Friction stir spot welding Damping materials Boron steels for SIPS bar Sandwich materials Gen 2 CosCone speaker 7 Foam in steel profiles Laser welded blanks & patchwork Nanoreinforced steel & PU nanocomposites Borit Structured steel CompuLite TM PUR substrate

11 CompoLite TM PU substrate CONCEPT Structural sandwich material based on PU foam core and PU-fibres reinforced skins CHARACTERISTICS Lightweight and good strength/weight ratio High bending stiffness and high dimensional stability Different reinforcing layers possible (glass fibre, basalt, natural fibres,...) High design freedom: integration possibilities (channels, fixture, other materials, ) flexible A-surface type: Colo-Fast, textile, good 3D formability in the moulding process different properties possible in 1 piece Cost-saving due to the 1-step process 8

12 PU Nanocomposites CONCEPT Addition of Zn oxide nanoparticles in PU formulation CHARACTERISTICS UV absorption leading to: improved colour stability broader UV protection spectrum No volatile organic compounds 9

13 Nano-reinforced steel CONCEPT Steel strengthening by non-alloy particles: oxide nanoparticles produced via different methods coating on nanoparticles to improve wettability nanoparticles dispersed in molten steel CHARACTERISTICS Steel strengthening by non-alloy particles Weight reduction as thickness can be reduced (higher steel strength) Concept in feasibility stage 10

14 Structured Steel CONCEPT Forming embossments in single sheet in a continuous process (patented) Assembly of 2 sheets (e.g. adhesive bonding) CHARACTERISTICS High stiffness, because of top/top set-up Lightweight (e.g. steel skins 2 x 0.25 mm) Extra energy adsorption during impact loading Additional features: allows internal (air) flow for heating and cooling advanced design look, different cavity shapes possible available in various steel grades (strength, coloured pre-coat) 11

15 Gen2 CosCone speaker CONCEPT Lightweight shallow speaker CHARACTERISTICS Lightweight (down to 125 g for standard 6.5 woofer or full range) because of the use of Nd magnet system & reduced material volume Shallow envelope (down to 30 mm for standard 6.5 woofer or full range) allows for more integration flexibility: compared to classic loudspeakers, a height reduction can be obtained that equals or exceeds the required mechanical excursion of the loudspeaker in its application Rigid membrane with controlled break-up matches classic cone performance Parameterization of membrane dimensions allows for design towards desired acoustics 12

16 Laser welded blanks & patchwork CONCEPT Remote laser stitch welding technology for hybrid blank solution LWB in combination with patchwork for local reinforcement enabling thickness reduction CHARACTERISTICS Weight reduction (10-15%) Easier production at OEM (less parts) Cost reduction Crash management Optimisation of welding parameters (robot path, penetration depth, gap, patch size, clamping, ) 13

17 Boron steels for SIPS bar CONCEPT Combination of press-hardened steel (PHS) and tailored blanks technology CHARACTERISTICS Weight reduction (up to 50% compared with a High-Strength Steel) Higher strength thanks to Usibor steel Higher energy absorption thanks to Ductibor steel Crash management Overall production costs reduction, thanks to: parts integration, blanking, stamping, post-assembling operations, reduction and better material consumption with improved sub-blanks cutting lay-outs 14

18 Foam in metal profiles CONCEPT Hollow metal profile filled with: aluminium foam different types of PUR foam CHARACTERISTICS Increased stiffness Extra energy absorption during impact loading Easy foam insertion 15

19 Steel-cord reinforced PU belt CONCEPT Steel cords in PU matrix Energy absorption element CHARACTERISTICS Weight reduction (450 g/m) and space saving Flexibility and easiness of assembly Universal usage by cutting to size at assembly line Adaptable length 16

20 Damping material - Legetolex CONCEPT Visco-elastic, structural damper with high damping performance and low weight It consists of a thin constraining layer (aluminium or glass cloth) and a self-adhesive synthetic rubber CHARACTERISTICS High-performance vibration damping Extremely lightweight, reducing overall vehicle weight Excellent adhesion on the vibrating structure thanks to special rubber compound Easy to apply even on curved or oily surfaces Application possible before and after ED-paint process Design, test and evaluation at Nitto Automotive Technical Centre (ATC) 17

21 Reinforcement material - Nitohard CONCEPT Heat-curing, epoxy/rubber based material for reinforcement of sheet metal Nitohard bonds tightly to the steel sheet The epoxy/rubber resin is foamed and hardened by the heat of the electro-coating line CHARACTERISTICS High reinforcement strength No sink marks on outer panel High adhesion at low temperatures Also applicable on curved surfaces Excellent workability Design, test and evaluation at Nitto Automotive Technical Centre (ATC) 18

22 Friction Stir Spot Welding CONCEPT Applied to join aluminium and steel Solid-state joining technique CHARACTERISTICS Combination of materials that are difficult to join Reduced internal stresses No fume or radiation emission during welding 19

23 Design / Engineering consultancy CONCEPT Coming trends analysis Structural innovations Styling guide Concept integration design - engineering CHARACTERISTICS Through concept and emotional sketches a concept evolves into reality Implementation of structural enhancements and intelligent feature integration Material/finish/colour advice to optimize end result 3D CAD concept to realisation 3D CAD rendered visualisations for marketing purposes Demonstrator model initiation and support 20

24 Physical door demonstrator leading to weight reduction (~20%) while adding new functionalities Door trim panel demonstrator 21

25 22

26 Integration of functionalities Sound box Integration of speaker and sound box in armrest Improved sound system performance because of: lower susceptibility to external parameter variation less influence of loudspeaker s suspension parts variation low efficiency loss higher transmission loss for external sound sources reduced vibration transfer to door structure and/or trim 23

27 Heating/Cooling Integration of structured steel in door carrier Heating and cooling within the door through the structured steel channels Air intake from the dashboard channelling Outlet towards rear passengers (through an extra ventilation hole in the door trim) Alternative for channelling in the body structure 24

28 Door demonstrator validation The door demonstrator has been validated considering various aspects Interior trim requirements Door sagging Door slamming Squeak & Rattle Torsional stiffness Thermal insulation Acoustic insulation Water tightness Impact resistance 25

29 26

30 Contact information Flanders DRIVE Oude Diestersebaan Lommel Belgium tel fax

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