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Composites technology for the automotive market continues to advance rapidly. Increasing knowledge of composite design, simulation tools, new materials and process equipment are all contributing to make composites better performing and more affordable for mass-produced vehicles. In particular, the high pressure resin transfer molding (HP-RTM) and related liquid compression molding (LCM) processes are enabling manufacturers to produce complex composite parts at shorter and shorter cycle times. This paper describes the development of an epoxy carbon fiber roof frame targeted for future vehicle production. Several composite processes were considered for the roof frame. The case illustrates that when the (product) design, material and process are considered together, a high-performing, cost-efficient part can be produced.

Phenolic resins that meet REACH compliance and contain lower free-formaldehyde are safer to handle, compound, and mold. These resin systems do not contain any styrene or require any fillers to achieve their rated fire resistance. A commercial phenolic sheet-molding compound (SMC) is presented that achieves a 2-minute cycle time and addresses the unique requirements in an electrified vehicle architecture. This new SMC material includes all the industrially relevant considerations including material processing, shelf life, and surface finish. Other topics such as material hybridization and comparison to incumbent materials also discussed. The resin system uses a water-based phenolic resole which is acid-cured. This chemistry presents several unique challenges and opportunities for the industry such as managing formulation pH and appropriate methods for quality control.

Composite materials have gained the attention of the automotive industry to substantially reduce vehicle weight, reduce CO₂ emissions and improve the fuel economy of next generation vehicles. Thermosetting matrix technology combined with glass or carbon fiber reinforcements are well suited for structural applications where mostly steel and aluminum are used today. However, the lack of fast production techniques and fast reacting matrix technologies have limited composites use to low volume production models. A new generation of epoxy resin systems has been developed that allows the rapid processing of structural composites for medium to high volume models. These advanced formulations maintain the excellent properties of traditional epoxy-based composites, yet the tested systems can process in a matter of minutes using modern manufacturing technologies such as the high pressure resin transfer molding (HP-RTM) process.