A Platform For Novel Lightweight Automotive Composite Design Bright Lite Structures LLC

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1 A Platform For Novel Lightweight Automotive Composite Design Antony Dodworth CTMO, Bright Lite Structures Keynote 5 ACCE Detroit September 2015

2 Zenos Car - December 2015 Birmingham, UK Auto Show 2

3 The Car Zenos video 5 minutes Long 3

4 Bentley T35 Concept 2009 Detail caption Pave Test 4

5 Background To Floor Development Proposed Floor Huntsman s spray system Floor Test piece T35-3 5

6 Asked Huntsman For A Better One Canfield Test Rig PU Paper Core Base Line 6

7 Polyurethane Systems for Structural Composites Michael Connolly, Daniel Heberer and David Bareis Huntsman Polyurethanes Auburn Hills, MI SPE Automotive Composites Conference Novi, MI September 11, 2015

8 HPU Composite Platform Six Base Resin Systems: Three RIMLine standard PUR systems Three Vitrox systems using a novel catalyst Each base resin system can be modified for a variety of applications or processing methods Reaction times and cure cycles Pot-life control extending from second to several hours Supplied with or without IMR as necessary The key defining feature of the six systems is the nominal Tg of the cured resin 8

9 Storage Modulus G' (Pa) Thermal Analysis by DMA of PU Composite Resin Systems 1.E+10 The materials named as PUR# or V# where # is the nominal Tg PUR refers to RIMLine and V refers to Vitrox resins 1.E+09 1.E+08 1.E+07 PUR-100 Tg=104C PUR-125 Tg=123C PUR-160 Tg=157C V-135 Tg=135 V-180 Tg=180C V-225 Tg=225C Low Tg Epoxy = 85 C Std Tg Epoxy = 140 C High Tg Epoxy =195 C (Not Shown) 1.E Temperature ( C) 9

10 Complex Viscosity (Pa s) Tunability of V180 Type Materials: Isothermal Viscosity Profiles at 80C Modified V180 Resin PUR 125 Inhibitor Level Decreasing Time (min) PUR system viscosity immediately increases exponential Vitrox systems have low, stable viscosity until snap cure Reactivity tunable enabling long working times for large parts 10

11 Tensile Properties of Neat PUR & Vitrox and Epoxy PUR and V-systems have good combination of modulus and strength with low or moderate working viscosity 11

12 Toughness of Neat PUR & Vitrox and Epoxy Toughness Improvement for a Given Tg Tg Increase for a Given Toughness 12

13 What System for Bright Light Structures Spray Processing? PU resins have demonstrated strong physical property performance with outstanding impact strength for a given resin Tg Novel Vitrox polyurethane-based resins with a unique reaction profile have been developed Adjustable pot-life Snap-cure after a tunable induction period Minimal viscosity increase prior to rapid and full cure Choose V135 for BLS Low initial viscosity enables easy impregnation of CF Working time tunable for prototype and production operations High toughness vs. comparable Tg epoxy Full cure possible out of mold (<140 C) Tg resin ~ Tg of honeycomb core material 13

14 Why Not An Epoxy? 14

15 Dodworth Design R & D Days Vehicle Design Concepts Multi Core Bonnet 7.2 Kg Test panels 15

16 Epoxy And PU Resin in same 120 GSM Ply Hard Surface 4.5 Kg head impact Construction High Tg 16

17 Prototyping of Test Parts Hand spreading video 17

18 BLS Was Born Leading the way to a world where auto chasses and other volume structural products are low cost, lightweight with a short lead time to market. 18

19 Zenos Early Designs Early CAD 19

20 Zenos Test Cars 20

21 Chassis Side Prototypes First articles from October 2014 CAD Design Sign Off To Parts in 8 Weeks 21

22 Chassis Side May

23 Seat Back Bulkhead 23

24 Seat Back Bulkhead 24

25 Seat Back Bulkhead 25

26 Manufacturing Process Spray wet out process Skin is recycled CF mat combined with multilayer NCF lay up Recycled polycarbonate core Roll fiber goods only WITHOUT preforming Simultaneous thermoforming and resin curing Extreme deep draw, complex parts in one step 26

27 November 2014 First Off Rear Bulkhead 27

28 Several Parts Later The Rule Applied Edge Detail 28

29 Zenos Seat Back Bulkhead Many Weeks Later Stacking Sequence 29

30 Wetting Pan Out By Hand Pan Material In White The Race Is On 30

31 Controlling the Speed PRESS CLOSING VIDEO 31

32 Finished Part Here Look At Cell Shape 32

33 33

34 Section Through Panel After Trimming Resin just into the cells 34

35 You Can See For Yourself 35

36 Metal Inserts Co-Molded In Pegged to tool Zenos Floor 36

37 Cold Bonded Inserts 37

38 Recycled Carbon Fiber Different suppliers 38

39 Costs 39

40 Tooling Concept 40

41 German OEM Front Bulkhead Development 41

42 Hand Spraying Blended Resin 42

43 Blended Resin For High Volume Auto Parts ( 30,000 PA) Skin is recycled CF mat combined with multilayer NCF lay up Bulkhead On Huntsman Stand 43

44 0.2mm Thick Aluminum Skin 44

45 Production Spray Equipment 7 Component Mixing 45

46 Production Cell 46

47 Production Cell Trials Video of cell running 47

48 Then You Close The Press 48

49 The Team 49

50 Thank You! Bright Lite Structures Contact: