Search Results (5)

Battery packs for new energy vehicles have evolved from simple load-bearing and protective assemblies into multifunctional safety structures integrating structural support, crash protection, thermal-runaway mitigation, flame retardancy, electrical insulation, electromagnetic interference shielding, waterproof sealing, and long-term reliability. Fiber-reinforced polymer composites are promising for upper covers, underbody shields, trays, cross beams, side frames, and local protective structures because of their low density, corrosion resistance, design flexibility, and functional-integration potential. However, composite-part performance is strongly governed by forming. Resin flow, impregnation, curing or cooling shrinkage, fiber orientation, filler dispersion, and interfacial bonding may induce voids, dry spots, resin-rich regions, delamination, warpage, and fiber waviness, thereby affecting load bearing, sealing, thermal protection, and durability. This review focuses on composite-forming technologies for new energy-vehicle battery packs. It summarizes component-level service requirements and material systems and compares representative forming routes, including sheet molding compound (SMC), prepreg compression molding/wet compression molding (PCM/WCM), resin transfer molding/high-pressure resin transfer molding (RTM/HP-RTM), vacuum-assisted resin transfer molding (VARTM), long-fiber thermoplastic direct processing (LFT-D), glass-mat thermoplastic (GMT), thermoplastic sheet forming, pultrusion, and multi-material joining. These routes are evaluated from six dimensions: material form, forming cycle, typical defects, representative mechanical performance, applicable components, and engineering maturity. The review further discusses defect mechanisms, performance effects, detection and control methods, and the roles of in-line monitoring, non-destructive testing, process simulation, machine learning, and digital twins in closed-loop quality manufacturing. Finally, engineering challenges are examined in multi-material joining, thermal-safety integration, low-carbon recycling, and standard certification. Composite-material battery-pack structures should therefore be developed as coordinated design and closed-loop manufacturing systems linking materials, processes, defects, performance, and validation. Full article

The one-step hybrid forming process is a novel process to fabricate a metal fiber-reinforced plastic (FRP) structure with reduced cycle time and cost compared to classical multi-step methods. It is realized by a combined forming tool for both sheet metal and FRP forming to create a hybrid part in only one step. During the forming process, sheet metal pre-coated with an adhesion promoter is joined with the FRP simultaneously. In this work, the crashworthiness and lightweight potential of a hybrid crash management system manufactured with a hybrid forming process were investigated. It includes the experimental behaviors and finite element analysis of glass mat thermoplastics (GMT), as well as aluminum–GMT hybrid structures, under dynamic axial crushing loadings. Beginning with the original geometry of a series aluminum crash management system, the design was optimized for a hybrid forming process, where an aluminum sheet metal part is reinforced by a GMT structure with a ground layer and additional ribs. The forming behavior and fiber filling of the GMT crash box were determined and analyzed as well. Finite element method optimization was used to obtain the optimal geometry of the hybrid crash box with the highest possible specific energy absorption and the utmost homogeneous force level over displacement. A hybrid bumper beam was also developed, along with other necessary connection parts, to join the beam with the crash box and the entire crash management system (CMS) to the vehicle body. The joining technique was determined to be a key factor restricting the lightweight potential of the hybrid CMS. Full article

Currently, the need for resource efficiency and CO₂ reduction is growing in industrial production, particularly in the automotive sector. To address this, the industry is focusing on lightweight components that reduce weight without compromising mechanical properties, which are essential for passenger safety. Hybrid designs offer an effective solution by combining weight reduction with improved mechanical performance and functional integration. This study focuses on a one-step manufacturing process that integrates forming and bonding of hybrid systems using compression molding. This approach reduces production time and costs compared to traditional methods. Conventional Post-Mold Assembly (PMA) processes require two separate steps to combine fiber-reinforced plastic (FRP) structures with metal components. In contrast, the novel In-Mold Assembly (IMA) process developed in this study combines forming and bonding in a single step. In the IMA process, glass-mat-reinforced thermoplastic (GMT) is simultaneously formed and bonded between two metal belts during compression molding. The GMT core provides stiffening and load transmission between the metal belts, which handle tensile and compressive stresses. This method allows to produce hybrid structures with optimized material distribution for load-bearing and functional performance. The process was validated by producing a lightweight hybrid brake pedal. Demonstrating its potential for efficient and sustainable automotive production, the developed hybrid brake pedal achieved a 35% weight reduction compared to the steel reference while maintaining mechanical performance under quasi-static loading Full article

The generation of pyrolysis liquids and gases with poor quality is a limiting factor for the development of the recycling process of fiber-reinforced plastic waste. In this article, the life cycle assessment (LCA) of an advanced two-step pyrolysis process to recycle glass fiber-reinforced polyamide waste is presented. First, the solid waste is pyrolyzed by heating up at 3 °C/min to 500 °C in a tank reactor. The generated volatiles are subsequently thermally cracked at 900 °C in a tubular packed bed reactor. The process is able to reclaim the glass fibers similarly to the conventional one reactor pyrolysis, while producing liquids and gases with better properties. The large quantity of oxygenated pyrolysis oils generated in the conventional pyrolysis are cracked into gaseous hydrocarbons, CO, CO₂ and a minor aqueous liquid. The pyrolysis gases become the main product of the process, presenting an interesting composition of hydrogen (39.9 vol.%), methane (22.5 vol.%), carbon monoxide (19.5 vol.%) and ethylene (10.8 vol.%). The LCA shows that advanced pyrolysis demonstrates better environmental performance than conventional pyrolysis, avoiding fossil resource scarcity and reducing global warming by half and human carcinogenic toxicity by one third. Full article

In compression molding using glass-fiber-mat-reinforced thermoplastic (GMT) sheets, a slightly longer compression waiting time from sheet placement on a lower mold to the start of sheet compression by an upper mold can cause incomplete filling due to a decrease in the sheet temperature. However, precise measurement techniques for compression waiting time have not been sufficiently established. A monitoring system was produced that includes pressure—temperature sensors mounted in a compression mold that can simultaneously measure the pressure and temperature of one local surface. Two types of distance sensors were also used to measure upper mold motion widely and precisely. Determination of compression waiting time was attempted by measuring the moment when the lower mold temperature slightly increases in response to contact with the melted GMT sheet and the moment when the melt pressure increases in response to compression by an upper mold. The results showed that compression waiting time could be precisely calculated using the profile data obtained. Moreover, it was also possible to observe the melt pressure overshoot that occurs depending on sheet stacking patterns and mold cavity shape, although in some cases, the overshoot was not observed. In conclusion, this study has demonstrated that the system is effective in monitoring the compression molding process widely and precisely. Full article