SOCA - Sustainably Optimised Composite Automotive

SOCA - 可持续优化的复合材料汽车

• 批准号: 10081882
• 金额: $ 71.53万
• 依托单位: JAGUAR LAND ROVER LIMITED
• 依托单位国家: 英国
• 项目类别: BEIS-Funded Programmes
• 财政年份: 2023
• 资助国家: 英国
• 起止时间: 2023 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=10081882
• 关键词: SOCA; Sustainably; Optimised; Composite; Automotive

Green mobility is key for a Net-Zero future. Polymer composites are a critical enabler to deliver lightweight solutions with ultimate performance. However, current manufacturing technologies are costly and inherently slow as well as limited in terms of fibre orientation distribution, given that current deposition and laying-up solutions (automated fibre placement - AFP, automated tape laying - ATL, tailored fibre placement - TFP) force straight/geodesic continuous fibre-paths. These issues result in labour intensive and prolonged manufacturing processes with low-productivity, increased energy consumption, production costs and environmental footprint, hindering wide adoption of composites in automotive. Also, whilst delivering lightweight solution in comparison to metal components, CFRP (Carbon Fibre Reinforced Plastic) have a higher embedded CO2e compared to their metallic counterparts. This is primarily due to the energy intensive process use in the production of the carbon fibre. Considering company and government commitment to a net-zero future it is instrumental to make efficient use of such material to balance components/vehicle structure mass, cost and CO2e targets.The SOCA project aims to bring to market CO2e-optimised/net-zero and lightweight composite technologies and body-structure for automotive electric vehicles (EVs) using the award-winning skeleton/flesh concept, which was successfully demonstrated during previous projects. The skeleton/flesh concept includes the use of low-cost/low-performance ''flesh'' material strategically reinforced with structural unidirectional (UD) carbon fibre tapes acting as a ''skeleton'' for the manufacturing of fibre reinforced parts (FRP). This is possible through iCOMAT's Rapid Tow Shearing (RTS) technology the world first automated composite manufacturing process that can place wide composite tapes along curved paths without generating defects. Effective fibre-steering allows alignment of fibres with the primary load-paths and complex geometries required in automotive application, leading to ultra-lightweight cost-effective components of ultimate performance.The SOCA consortium will develop and validate through structural testing and simulation both virtual and physical demonstrators using an existing body structure concept. The aim is to exploit the technology through low-volume in the short-term before expanding to higher volumes following successful demonstration and adoption in low-volume.The implementation of SOCA technologies is expected to reduce body-structure environmental footprint, mass and can enable further vehicle mass reductions due to additionally induced mass savings in secondary systems such as batteries.Furthermore, enabling the use of low-CO2e FRP from recycled fibre and optimised UD laying, will drastically reduce the environmental footprint of current automotive FRP component, specifically when extensively using carbon fibre.

绿色移动性是零净未来的关键。聚合物复合材料是提供具有终极性能的轻量化解决方案的关键推动因素。然而，鉴于当前的沉积和铺层解决方案（自动纤维铺放- AFP、自动胶带铺放- ATL、定制纤维铺放- TFP）迫使直线/测地线连续纤维路径，当前的制造技术成本高昂，而且固有速度缓慢，而且在纤维取向分布方面受到限制。这些问题导致劳动密集型和长时间的制造过程，生产率低，能源消耗，生产成本和环境足迹增加，阻碍了复合材料在汽车中的广泛采用。此外，与金属部件相比，CFRP（碳纤维增强塑料）在提供轻质解决方案的同时，与金属部件相比，CFRP（碳纤维增强塑料）具有更高的嵌入式CO2 e。这主要是由于碳纤维生产中使用的能源密集型工艺。考虑到公司和政府对净零未来的承诺，有效利用此类材料有助于平衡组件/车辆结构质量、成本和CO2 e目标。SOCA项目旨在将CO2 e优化/净零和轻质复合材料技术以及采用屡获殊荣的骨架/血肉概念的汽车电动汽车（EV）车身结构推向市场，这在之前的项目中已成功演示。骨架/肉的概念包括使用低成本/低性能的“肉”材料，战略性地用结构单向（UD）碳纤维带加强，作为制造纤维增强部件（FRP）的“骨架”。iCOMAT的快速牵引剪切（RTS）技术是世界上第一个自动化复合材料制造工艺，可以将宽复合材料带沿着弯曲路径放置而不会产生缺陷。有效的纤维转向允许纤维与汽车应用中所需的主要载荷路径和复杂几何形状对齐，从而产生具有最终性能的超轻量化成本效益组件。SOCA联盟将通过结构测试和模拟，使用现有车身结构概念开发和验证虚拟和物理演示器。其目的是在短期内通过小批量开发该技术，然后在小批量成功示范和采用后扩大到更高的产量。SOCA技术的实施预计将减少车身结构的环境足迹和质量，并由于电池等二次系统的额外诱导质量节省而能够进一步减少车辆质量。此外，通过使用来自再生纤维的低CO2 e FRP和优化的UD铺设，将大大减少当前汽车FRP部件的环境足迹，特别是在广泛使用碳纤维时。