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GB2543572A - A component for a vehicle - Google Patents

A component for a vehicle Download PDF

Info

Publication number
GB2543572A
GB2543572A GB1518808.9A GB201518808A GB2543572A GB 2543572 A GB2543572 A GB 2543572A GB 201518808 A GB201518808 A GB 201518808A GB 2543572 A GB2543572 A GB 2543572A
Authority
GB
United Kingdom
Prior art keywords
layer
structural component
vehicle
carbon
fibre composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1518808.9A
Other versions
GB201518808D0 (en
Inventor
Gordon Murray Ian
Coppuck Frank
John Smith Andrew
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gordon Murray Design Ltd
Original Assignee
Gordon Murray Design Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gordon Murray Design Ltd filed Critical Gordon Murray Design Ltd
Priority to GB1518808.9A priority Critical patent/GB2543572A/en
Publication of GB201518808D0 publication Critical patent/GB201518808D0/en
Priority to PCT/GB2016/053286 priority patent/WO2017068357A1/en
Publication of GB2543572A publication Critical patent/GB2543572A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A structural component 10 for a vehicle, for example a shear panel, door pocket or seat substrate, comprises a first layer 12 of carbon fibre composite material, a second layer 14 of paper honeycomb material and a third layer 16 of short-fibre composite material, most preferably comprising carbon fibre. The honeycomb 14 is arranged between first layer 12 and third layer 16. A lacquer layer 18 is provided on part of a visible surface of a carbon fibre composite layer 16. The carbon fibres may be arranged in a random mat or a woven fabric. Suitably, the carbon fibres in first or third layers 12, 16 may contain a portion of recycled or off-cut carbon fibres and paper honeycomb 14 may contain recycled paper. Component 10 may be lightweight, allowing a lighter overall weight of a vehicle, while providing a cosmetically acceptable surface without trim panels.

Description

A component for a vehicle
FIELD OF THE INVENTION
The present invention relates to materials for use in the manufacture of vehicles, especially light-weight, energy-efficient cars. More especially, the present invention relates to structural components for vehicles.
BACKGROUND ART
Carbon fibre composite materials are known for use in various fields, including components for vehicles. However, the method by which the composite materials are sometimes made can be wasteful of raw materials and energy. Furthermore, carbon composite materials can be combined with other materials to form improved materials. In the field of road vehicles, especially cars, it is desirable to form components for vehicles which are stronger for their weight and with an improved environmental footprint.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to structural component for a vehicle having a first layer of carbon fibre composite material, a second layer of honeycomb material, and a third layer of carbon fibre composite material, in which the second layer is arranged between the first and third layer, and in which at least one of the carbon fibre composite layers has a lacquer layer on at least part of a visible surface of it. A structural component for a vehicle for the purpose of this invention is a part of a vehicle which provides support and/or stability to the chassis of that vehicle. Examples of structural components may be a shear panel, a door inner panel, a seat substrate or frame, each part of a vehicle. Structural components enable the vehicle chassis to absorb or redirect forces such as from manoeuvres of or impacts to the vehicle.
One advantage of such an arrangement is that such a structural component provides a good strength for its low weight. Furthermore, such a component may have as its first visible layer a finished surface. Thus no embellishments nor decorative trim are required. Both advantages thus allow a lighter overall weight for a vehicle including such a structural component than might otherwise be the case, with the resulting improvements in fuel efficiency or energy efficiency.
The carbon fibres may be formed of a random mat, or a woven fabric.
One or more of the layers may be at least partially made with recycled material. For example, at least a portion of the carbon fibres of one or both composite layers may be made from previously used carbon fibre composite material from which the carbon fibres have been removed and used to create or contribute to a fresh mat. Such fibres may also be obtained from carbon fibres which are left over from elsewhere, such as off-cuts from, for example, pieces of woven carbon fibre which have been broken up and their fibres used to form or contribute to a mat. Using recycled or left over carbon fibres reduces the need to produce fresh carbon fibres, and reduces the need to dispose of used or left over carbon fibres. Thus, there is a significant saving in terms of energy, material and disposal needs.
The honeycomb material may be of a suitably lightweight material such as paper. The paper honeycomb layer may be made from recycled paper. A further advantage of such a selection of materials is that the materials themselves may be subsequently recycled. Thus, selecting materials which may be constructed from recycled materials and which may be subsequently recycled further reduces the energy required and the overall environmental footprint of such structural components.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described by way of example, with reference to the accompanying figures in which:
Figure 1 shows a diagrammatic cross-section of a portion of a structural component according to the present invention;
Figure 2 shows a perspective view of a part of a vehicle chassis including structural components according to the present invention; and
Figure 3 shows a plan view of a part of a vehicle chassis including structural components according to the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Figure 1 shows a portion of a structural component 10, in a first carbon fibre composite layer 12, a second paper honeycomb layer 14, and a third carbon fibre composite layer 16 are arranged so that the paper honeycomb layer 14 is sandwiched between the two carbon fibre layers 12 and 16. The carbon fibre composite material layers 12 and 16 have a random mat of short carbon fibres within a matrix (not shown). At least a portion of a visible exterior surface of one of the carbon fibre composite layers has a layer of lacquer 18 thereon.
Figures 2 and 3 show a part of a vehicle chassis 100 in which there are shear panels 20 which each have a structure according to the invention and as described with reference to Figure 1. The vehicle chassis 100 generally comprises a superstructure of interconnected tubular members 22 with other vehicle elements connected thereto. The superstructure of tubular members 22 is not an essential part of the present invention, but the structural components of the present invention, such as the shear panels 20 of the example embodiment described, are designed to work in conjunction with such a superstructure, but are not exclusively operable therewith. Visible parts of the shear panels 20 are provided with a layer of lacquer.
Generally, in a chassis that combines metallic and composite materials (such as that shown in figures 2 and 3), the metallic parts (e.g. the superstructure 22) provide hard fixing points for items such as the engine, transmission, suspension, roll-over protection and the like. This enables the large point forces to be transmitted into the chassis without damaging the composite structure. Composite panels according to the present invention then bridge the gaps or apertures between the metallic parts to transmit forces between them. In some chassis arrangements, such as the McLaren FI and those that followed it, the metallic parts comprise inserts that are co-moulded in the composite material structure. In others, such as our GB2265483, the metallic parts comprise a three-dimensional framework forming the superstructure of figures 2 and 3 and the composite parts comprise smaller panels that are adhesively attached to the framework to act as shear panels reinforcing the framework and assisting in the transmission of forces around the chassis.
Thus, the invention provides a particularly lightweight composite section for use in various types of vehicle chassis. It can have a very low environmental footprint by using minimal amounts of already-recycled material. It can further assist in saving weight from the vehicle by obviating the need for trim panels that conceal the chassis, as the lacquered surface presents a cosmetically-acceptable first-surface finish.
It will of course be understood that many variations may be made to the above-described embodiment without departing from the scope of the present invention.

Claims (10)

1. A structural component for a vehicle having a first layer of carbon fibre composite material, a second layer of paper honeycomb material, and a third layer of short-fibre composite material, in which the second layer is arranged between the first and third layer, and in which at least one of the carbon fibre composite layers has a lacquer layer on at least part of a visible surface of it.
2. A structural component according to claim 1, in which the carbon fibres are arranged as one of a random mat and a woven fabric.
3. A structural component according to claim 1 or claim 2, in which at least a proportion of the carbon fibres of one or both of the first and third layers are made from recycled carbon fibres.
4. A structural component according to any preceding claim, in which the paper honeycomb is made from recycled paper.
5. A structural component according to any preceding claim, in which the materials used are recyclable.
6. A structural component according to any of claims 1 to 6, in which the component is a shear panel.
7. A structural component according to any of claims 1 to 6, in which the component is a door pocket.
8. A structural component according to any of claims 1 to 6, in which the component is a seat substrate.
9. A vehicle including a structural component according to any preceding claim.
10. A structural component for a vehicle as described herein and with reference to the drawings.
GB1518808.9A 2015-10-23 2015-10-23 A component for a vehicle Withdrawn GB2543572A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB1518808.9A GB2543572A (en) 2015-10-23 2015-10-23 A component for a vehicle
PCT/GB2016/053286 WO2017068357A1 (en) 2015-10-23 2016-10-21 A component for a vehicle

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1518808.9A GB2543572A (en) 2015-10-23 2015-10-23 A component for a vehicle

Publications (2)

Publication Number Publication Date
GB201518808D0 GB201518808D0 (en) 2015-12-09
GB2543572A true GB2543572A (en) 2017-04-26

Family

ID=55130146

Family Applications (1)

Application Number Title Priority Date Filing Date
GB1518808.9A Withdrawn GB2543572A (en) 2015-10-23 2015-10-23 A component for a vehicle

Country Status (2)

Country Link
GB (1) GB2543572A (en)
WO (1) WO2017068357A1 (en)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US42593A (en) * 1864-05-03 Improvement in oil-cans
US196175A (en) * 1877-10-16 Improvement in fence-posts
JPH05201358A (en) * 1992-01-29 1993-08-10 Mitsubishi Rayon Co Ltd Monocock structure for vehicle
JP2011224873A (en) * 2010-04-20 2011-11-10 Mitsubishi Plastics Inc Fiber reinforced resin-made sandwich structure
DE102012104542A1 (en) * 2012-05-25 2013-11-28 Webasto Ag Vehicle bodywork component for use in roof region of motor vehicle, has composite material with carrier and outer skin, where carrier has core with outer skin border on both sides, which is made from carbon-fiber-reinforced plastic
CN203611507U (en) * 2013-11-27 2014-05-28 苏州芳磊蜂窝复合材料有限公司 Honeycomb sandwich plate provided with carbon fiber paper steel panel
DE102013017955A1 (en) * 2013-10-29 2014-08-14 Daimler Ag Motor car with floor element has deck element that is formed of fiber composite material and is connected with stiffener structure which is designed as honeycomb core or as foam core

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6508910B2 (en) * 2000-05-18 2003-01-21 Hexcel Corporation Self-adhesive prepreg face sheet for sandwich panels
DE102012216545A1 (en) * 2012-09-17 2014-05-28 Bayerische Motoren Werke Aktiengesellschaft Motor vehicle has flat component with shell construction for arrangement in body of motor vehicle, where flat component has outer layer, core and inner layer, and outer layer is made from fiber-reinforced plastic

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US42593A (en) * 1864-05-03 Improvement in oil-cans
US196175A (en) * 1877-10-16 Improvement in fence-posts
JPH05201358A (en) * 1992-01-29 1993-08-10 Mitsubishi Rayon Co Ltd Monocock structure for vehicle
JP2011224873A (en) * 2010-04-20 2011-11-10 Mitsubishi Plastics Inc Fiber reinforced resin-made sandwich structure
DE102012104542A1 (en) * 2012-05-25 2013-11-28 Webasto Ag Vehicle bodywork component for use in roof region of motor vehicle, has composite material with carrier and outer skin, where carrier has core with outer skin border on both sides, which is made from carbon-fiber-reinforced plastic
DE102013017955A1 (en) * 2013-10-29 2014-08-14 Daimler Ag Motor car with floor element has deck element that is formed of fiber composite material and is connected with stiffener structure which is designed as honeycomb core or as foam core
CN203611507U (en) * 2013-11-27 2014-05-28 苏州芳磊蜂窝复合材料有限公司 Honeycomb sandwich plate provided with carbon fiber paper steel panel

Also Published As

Publication number Publication date
WO2017068357A1 (en) 2017-04-27
GB201518808D0 (en) 2015-12-09

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Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)