Energy-efficient structural materials for mass-production of lightweight vehicles

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Research Collection

Presentation

Energy-efficient structural materials for mass-production of lightweight vehicles

Author(s):

Schneeberger, Christoph Publication Date:

2019-11-07 Permanent Link:

https://doi.org/10.3929/ethz-b-000376813

Rights / License:

In Copyright - Non-Commercial Use Permitted

This page was generated automatically upon download from the ETH Zurich Research Collection. For more information please consult the Terms of use.

ETH Library

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Hybrid bicomponent fibre

Energy-efficient structural materials

for mass-production of lightweight vehicles

20 µm

Thermoplastic polymer

Glass

(“plastic”)

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Doctoral candidate at ETH Zurich

└ 2015 to 2020

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Christoph Schneeberger

MSc & BSc ETH

in Mechanical Engineering

SCCER Mobility Capacity Area A3

“Minimization of Vehicular Energy Demand”

└ Direct consolidation via hybrid yarn route

Laboratory of Composite Materials and Adaptive Structures

└ Hybrid bicomponent fibres

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3

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31.7%

20.2%

18.4%

13.2%

8.9%

7.6%

Contributions to Swiss GHG emissions in 2016 by sector

Transport Industry

Households Agriculture Services Waste

Source: Swiss Federal Office for the Environment FOEN

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71.9%

15.9%

0.8%

0.7%

0.2%

10.4%

Contributions to GHG emissions for Swiss transportation sector

Road based passenger

Road based freight Aviation (domestic) Water

Rail Others

Source: Swiss Federal Office for the Environment FOEN

5

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0 200 400

500 1500 2500

Climate change [gCO 2/vkm]

Vehicle mass – [kg]

Sensitivity of climate change caused by passenger cars to their total mass

Diesel combustion Gasoline combustion Gas combustion

Synthetic gas combustion Hybrid electric (gasoline) Plug-in hybrid

Battery electric Fuel cell electric

Data adapted from Brian Cox, doctoral thesis, ETH Zürich, 2018. (Trendlines shown)

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Data taken from CES EduPack software

Fibre-reinforced polymer composites (FRP)

Sources: Wbcomposites, BASF

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Production/cradle Use/life

End of life/grave?

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Production/cradle Use/life

End of life/grave?

Fibre-reinforced

thermoplastic composites

No curing reaction Forming & re-forming

Lightweight

Recyclable

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Reduce vehicular energy demand through lightweighting

CA A3

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State of the art

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Rapid stamp forming of thermoplastic composites

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State of the art fast part production

Heating Forming Consolidation and solidification

Demolding Intermediate

material

Composite part

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State of the art intermediate materials

Source: C. Schneeberger, J. C. H. Wong, and P. Ermanni. Hybrid bicomponent fibres for thermoplastic composite preforms. Compos. Part A Appl. Sci. Manuf.103, 69–73 (2017).

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Proposed solution

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Hybrid bicomponent fibres

Core fibre radius 𝑟𝑟_𝑓𝑓 and sheath thickness h.

Source: C. Schneeberger, J. C. H. Wong, and P. Ermanni. Hybrid bicomponent fibres for thermoplastic composite preforms. Compos. Part A Appl. Sci. Manuf.103, 69–73 (2017).

Full wet-out Conforming

to complex geometries

High volume Avoiding

impregnation

flows

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Manufacturing approach

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Glass melt spinning

Bushing

Gathering shoe Glass furnace

Take-up winder

Newly spun glass fibres

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Continuous in-line coating process

Kiss-roll coating with polymeric solution

Wetted fibers

Dry bicomponent fibers Drying

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Pilot plant

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Glass re-melt bushing

Resistance heating contact

Resistance heating contact Transformer

Vibrating glass feeder

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Vibrating glass feeder with reservoir

E-glass (borosilicate glass)

Sigmund Lindner SiLibeads SL

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Top assembly

Fume cabinet

Exhaust

Control cabinet

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Kiss-roll

Solution reservoir and pump

Take-up winder Polycarbonate (PC)

Covestro (Makrolon 3108)

dissolved in

Trichloromethane (CHCl₃)

Sigma-Aldrich

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200µm

Mostly cylindrical coatings

Regions with thicker coatings

Imprint from paper on bobbin 𝑣𝑣_𝑓𝑓 ≈ 61% (TGA)

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Stamp forming

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Bicomponent fibre cake

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Hydraulic hot press

Convection oven

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Lower platen

Upper platen

Lower heated press surface

Preform sample Material frame

Frame suspension

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Oven open 00.0 s Material out 02.2 s Material in press 04.9 s Press closed 09.2 s Press open 21.2 s Transition: 9.2 s

Holding time in press t_h: 12.0 s

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200 µm

Most voids as microcracks at fibre-matrix interface

Few examples of entrapped air

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5 12 t_h [s]

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0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35

280 300

Void content [%]

T₀ [°C]

120 145

T_p [°C]

Main effects on void content

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0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35

Void content [%]

Limit for advanced aerospace applications 0.50

0.40 0.45

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Conclusions

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Stamp forming of bicomponent fibre preforms

Low cycle times (12-22 s)

Low void content

Aerospace

quality laminates

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Continuous in-line coating process

Scalable Yields

separately coated fibers

Robust High volume

throughput

possible

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Achievements & outlook

Proof of coating method ✔ Proof of in-line

process ✔

Parallel coating of many filaments ⏳

Proof of consolidation behavior ✔

Life cycle assessment of automotive part production ⏳

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Recyclable

Lightweight

Efficient production

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This research was supported by:

 Swiss National Science Foundation (Project № 200021_165994).

 Swiss Competence Center for Energy Research (SCCER) Efficient

Technologies and Systems for Mobility.

 Dow Europe GmbH.

 Leibnitz Institute of Polymer Research Dresden.

 Covestro Deutschland AG.

Research by:

 Christoph Schneeberger

 Nicole Aegerter

 Shelly A. Arreguin

 Joanna C.H. Wong

 Paolo Ermanni

Many thanks to our partners within SCCER Mobility CA A3:

 SEM images taken at Complex Materials lab (ETHZ)

 Rheometry performed at Soft Materials lab (ETHZ)

 Surface tension measurements made at Institute of Polymer Engineering (FHNW)