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Lightweight Composite Panel
But the technology is not new. For many years composites or sandwich panels have been used in the construction of civil and military aircraft and more recently they have been used in racing cars, shipbuilding and even special architecture. A typical Boeing civil airliner can contain up to 5-15% composite panels, although Boeing recently announced that the new 7E7 will contain up to 50% composite, making it the lightest to maintain the best patience.
The success of integrated technology in the aviation sector has made it attractive to other industries looking to apply the benefits. One of the most important things for the trucking industry is that the main composite material is lighter than steel and aluminum with an average saving of up to 40% of iron and 20% of aluminum.
Currently, composite technology can be applied to body panels and accessories, front panels, floors, engine blocks, cargo liners, car chassis, bumpers, fuel tank supports, heat-resistant areas such as inlet manifolds, cooling modules, and oil pans… The heavy wood or heavy metal of the trailer can be replaced with sandwich panels to reduce even more pounds and add extra payload and longer trailer life. The difference in the materials used and in the production process allows the panel to be assembled into a flat or curved shape that has the highest strength and weight of any structural material available on the market.
Simply replacing a Class 8 sleeper box with custom-designed composite panel technology can reduce overall vehicle weight by up to 850 pounds, reduce weight and fluid resistance, and increase payload. .
In addition to light elements, sound dampening and insulation create a peaceful environment in which to sleep; Resistance to corrosion, and durability in general is also high on the scale.
Panels are formed when two materials are combined to form a material that is stronger than one of the two base materials. The panel itself is heated and thermo bonded to the matrix or base; the matrix connects the fibers to a stronger material, called reinforcement. The reinforcement can be made of glass fiber, aramid and carbon while the matrix can consist of polyester resin, vinyl ester resin, or epoxy resin, as well as many lightweight fiber materials. The separation of the skin through this center of the lower neck increases the moment of inertia of the beam or panel with a small increase in weight, producing a very efficient structure. During the extensive use of strong adhesives, the composite panel is well integrated providing a higher improvement in connection with conventional riveting or welding processes. Staying ahead of routines allows the industry to see tangible savings associated with lowering the cost of direct labor, materials, equipment and especially the elimination of problems or expensive rust and corrosion requirements. .
In general, the strength of the composite panel depends on the overall size, the surface material used, and the density of the cells inside, the thicker the core, the higher the stiffness and panel strength. By carefully choosing the reinforcement, matrix and manufacturing process, manufacturers can produce industry-specific composite panels. Composites designed for heavy commercial applications such as aircraft manufacturing, aerospace industry, oil extraction and military markets use strong and continuous fibers such as polyurethane foam or other active materials to ensure a rigid panel that withstands wear and tear due to stress. mechanical pressure. For low strength and stiffness or low stress such as automotive, marine and industrial areas, a non-dispersive fiber matrix such as paper or card can be used to ensure the best weight strength for of specific applications.
Through different structures and thicknesses, the compressive and tensile strength and resistance to deflection withstand damage from stones and debris as well as the stress of loading and unloading. to a minimum. If damaged, panel replacement is quick and easy and can be repaired at most body shops.
Generic composite panels are generally defined as:
Some general benefits are:
- Lighter (but stronger) equipment provides lower fuel consumption
- Can be configured for many specific applications
- Relatively fast application time
- Noise dampening blocks noise from outside the interior
- Resistant to harmful chemicals and heat
- They last longer
- Structural noise is reduced
From a manufacturing or engineering perspective:
- When shock and impact are an issue, the size of the honeycomb cells can be adjusted to achieve different compressive strengths.
- Working prototypes using laminated panels and sandwich panels can be manufactured within 4-6 weeks from start. The production process is geared towards maximum efficiency and optimal implementation time
- The insulation value (R value) can range from 2.5 to 6 depending on the thickness of the panel. Special customer requirements can be achieved by using special cores and facings
- The variety of materials used to manufacture custom panels makes them an attractive option for truck manufacturers.
- The design capabilities of the body and door panels, lids, roof panels, bonnets and spoilers allow for a significant reduction in fluid drag and rolling resistance. Continuous research and development provides continuous advances in integrated performance and expands the range of applications. The transportation industry is embracing composite technology that may replace wood and metal as the materials of choice.
Edison Reis, B.Sc. Eng.
Engineering & Quality Assurance Manager
Canadian Commercial Vehicles Corp.
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