Customer-Driven Development of an Ultra Low-Density Class A SMC Resin System

摘要

The automotive industry is under pressure to meet the National Highway Traffic Safety Administration's recently augmented Corporate Average Fuel Economy (CAFE) requirements. The goal of CAFE is to continue to reduce energy consumption by increasing the fuel economy of cars and light trucks. However, the most recent standard rapidly increases the fuel efficiency requirements in a short span of time. One approach automotive producers are taking to meet CAFE standards is to design and produce lighter vehicles. According to the U.S. Department of Energy's Vehicle Technologies Office, a 10% reduction in vehicle weight can result in a 6 to 8% fuel-economy improvement. Composite sheet molding compound (SMC) has provided a lightweight, Class A option for OEMs over the past years (for parts such as in Figure 1). However, as SMC density (and therefore, part weight) has dropped, there has been a corresponding drop in strength and toughness. Traditional routes to toughen the material have resulted in less-than-optimal finishes.