Automotive Doors – New Technology and TrendsEmissions from road transport increased by 26% between 1990 and 2008, withpass...
conventional door systems at no extra cost, and has several other advantageousbenefits. Wood-fibre reinforced plastic is a...
Magnesium DoorsThe use of magnesium for car body parts, including doors, to replace steel could bean option for manufactur...
Mercedes-Benz F125!Source: Daimler TechnicityOne highly innovative design for a door system is the Mercedes-Benz F125! Con...
The F125! Is a design inspired by the thought of what the car may evolve into bythe year 2025, and gives an insight into o...
Magnesium doors are another trend which is likely to undergo rapid development inthe industry, as they offer substantial w...
References:    (1) http://ec.europa.eu/clima/policies/transport/vehicles/cars/faq_en.htm    (2) http://www.brose.de/ww/en/...
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Automotive doors: New technology and trends

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Automotive doors: New technology and trends

  1. 1. Automotive Doors – New Technology and TrendsEmissions from road transport increased by 26% between 1990 and 2008, withpassenger cars currently responsible for 12% of overall EU emissions of CO2 (1).The EU introduced regulations for passenger cars in 2009 with targets for emissionlevels that manufacturers must adhere to. By 2015 passenger cars should havemaximum emissions of 130g CO2/km, with a further target of 95g CO2/km to beachieved by 2020. Limits for the emissions of light commercial vehicles were addedto the legislation in 2011, stating that the maximum should be no more than 175gCO2/km by 2017 and 147g CO2/km by 2020.These targets for reduced emissions are one of the biggest drivers of innovation inthe automotive manufacturing sector, with weight reduction at the forefront ofdevelopment. To meet the regulations each car manufacturer is assessed on theemissions of their overall fleet. Every new car registered is given an indicativeemission level based on its mass, and manufacturers must ensure that the averagemass of all its cars is in line with the emission allowance. Heavier cars are targetedfor greater emissions than lighter cars, so the reduction in the mass of their overallfleet will help manufacturers to comply with the legislation.TrendsThe automotive door sector is one area in which manufacturers are looking toreduce overall weight by using alternative materials and new manufacturingconcepts. Door suppliers are continually striving to improve the design andengineering of their products, and any reduction in weight will need to be integratedwith other areas of innovation such as noise reduction, closure and sealing systemsand keyless technology.BroseThe automotive supplier Brose introduces a new concept in design last year whenthey introduced a door system manufactured from wood-fibre reinforcedpolypropylene (2). The door structure provides a 6% weight saving against------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  2. 2. conventional door systems at no extra cost, and has several other advantageousbenefits. Wood-fibre reinforced plastic is a sustainable material which is carbonneutral. The use of renewable and recyclable materials is another trend in theindustry, again in the pursuit of carbon emissions reduction.Pictured below, the door system offers manufacturers protection from pricefluctuations in raw materials, such as plastics derived from crude oil. The carrierplate is manufactured from polypropylene which has been reinforced with 40%wood fibre. In comparison with a glass-fibre reinforced door system, the Brosedesign reduces the amount of plastics used by 20%.Source: BroseCrash testing results showed that the door system offers the same level of safety asa glass-fibre reinforced solution; and the integrated doors also contribute to betterthermal and acoustic insulation.------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  3. 3. Magnesium DoorsThe use of magnesium for car body parts, including doors, to replace steel could bean option for manufacturers as it offers great potential for weight saving (3).Magnesium parts can be manufactured which provide a similar rigidity to steel, butare up to 50% lighter. Researchers at the Die Fraunhofer Institute for Machine Toolsand Forming Technology IWU designed and produced an example door last yearwhich was showcased at the Hanover Messe trade fair in April. The magnesium doorweighs just 4.7kg compared with a similar steel door at around 10.7kg.The advantage of using magnesium is that it is a resource which is available in largequantities world-wide, it can be easily moulded during production, and it possessesmuch the same properties as steel. Engineers at the Fraunhofer Institute havedeveloped specific moulding technologies for wrought magnesium alloys, and it isthe processes they are developing which may lead to the use of magnesium in massproduction for car parts.Tailored BlanksThe use of optimised sheet metal parts, manufactured specifically, is anothermanufacturing option which can reduce weight and offers a variety of benefits forcar makers, such as reduced cost and enhanced crash protection. One companysupplying products to the automotive industry is ThyssenKrupp (4). They producetailored blanks constructed from individual sheets of steel of differing thickness,strength and coating which are joined by laser welding. By tailor-making theproducts, ThyssenKrupp ensure that the completed part has the right grade of steelin the right place.The tailored parts reduce the need for reinforcement and overlapping joints withinthe part, so require less material which reduces weight. The targeted use of steelwith different properties also helps to lower cost as well as weight. The moreexpensive materials are used only when necessary, while cheaper grades of steelcan be used in non-essential areas. The structural strength of the vehicle and thecrash performance can also be improved through the use of tailored blanks fordoors. The thicker, high strength steels are used in areas of high tension and areaswhich may suffer the impact in a crash.------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  4. 4. Mercedes-Benz F125!Source: Daimler TechnicityOne highly innovative design for a door system is the Mercedes-Benz F125! Conceptvehicle, pictured above. Engineers designed the car with a view to vehicles in twogenerations time, and have developed several visionary features, not least the gullwing doors. The research car has been built so that designers can study the futurefor automobiles and obtain new knowledge about how different innovations work inpractice.The doors are of a light weight and high strength CRP construction, while crashprotective systems built into the door allow the removal of the B pillar. The doorsallow access to all four seats of the vehicle at the same time, and can be controlledfrom the front or rear seats of the car. Opening and closing of the doors iscompletely contact-free from the outside, as simple wiping gestures can control allof the functions, with a control element built into the rear side window. The doorscan be opened or closed from within the car by the simple touch of a button, whileoutside, it is possible to use a smartphone to unlock and open the doors.------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  5. 5. The F125! Is a design inspired by the thought of what the car may evolve into bythe year 2025, and gives an insight into one way in which the automotive door maydevelop.Fibre Reinforced PlasticFibre-reinforced plastics are becoming more and more commonplace in carmanufacturing as the trend towards weight reduction continues. Electric cars inparticular will benefit from the use of lighter materials due to the weight of theheavy battery packs that they have to carry. Market research firm Lucintel (5),revised its prediction for the growth of the carbon-fibre plastics market in its mostrecent market report, “Growth Opportunities in the Carbon-Fibre Market 2010-2015”. They estimated that the market could grow by 13% per year over the fiveyear period. Automotive manufacturing is sure to contribute to the growth in thesector, and research is ongoing amongst manufacturers to develop more and moreparts and components from composite plastics.SummaryThe EU requirements for carbon emissions from passenger vehicles is pushingmanufacturers into developing newer and innovative technologies which can reduceweight and contribute towards the targets. Door manufacturers have several otherdemands from consumers which are also being developed alongside weightreduction initiatives. Consumers and therefore car makers, demand moretechnology in the door, as well as greater safety and security, and enhanced noisereduction for greater comfort.The challenge for door manufacturers is to integrate all of these requirements intodoor systems which also save weight. The Brose development of a wood-fibrepolypropylene door system is one example of the types of door structures that couldsoon be in serial production. The doors offer weight saving compared to steel doorsystems, and provide extra thermal and acoustic insulation. The use of asustainable material such as wood-fibre has several advantages and is likely to be acontinuing trend in the coming years. Using renewable materials helps towards theEU’s overall carbon emission targets, and lessens the reliance on fluctuatingmaterial prices due to crude oil prices.------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  6. 6. Magnesium doors are another trend which is likely to undergo rapid development inthe industry, as they offer substantial weight savings of up to 50% compared withsteel doors. Techniques being developed at the Fraunhofer Institute can producematerials which have similar strength and rigidity to steel, and the processes theyare developing could see magnesium being put to use in mass production in theautomotive industry over the next few years.The Mercedes-Benz F125! Research vehicle offers a glimpse into the future of automanufacturing, with a car designed with the 2025 and the evolvement of thepassenger car in mind. The gull wing concept completely removes the B pillar, andthe door is constructed from a light weight CRP material. Several technologies havebeen integrated into the door with touch button controls and contact-free openingfrom the outside via a smartphone.Ultimately, manufacturers must develop designs in the future which can meet thedemand for lighter doors, with better crash protection, enhanced acousticperformance, and integrated technology. Colin PawseyColin Pawsey’s background and experience is in the water heating industry, with a focus ontechnical data analysis and energy efficient products for both commercial and residentialsectors. He also works as a freelance journalist focussing on renewable and sustainableresources, energy efficiency, and consumer information.------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de
  7. 7. References: (1) http://ec.europa.eu/clima/policies/transport/vehicles/cars/faq_en.htm (2) http://www.brose.de/ww/en/pub/press/content12499.htm (3) http://www.fraunhofer.de/en/press/research-news/2011/april/resource- friendly-car-manufacturing.html (4) http://www.tailored-blanks.com/en/products/tailored-products/thyssenkrupp- tailored-blanks.html (5) http://www.lucintel.com/ Want to know more about automotive doors? Check out our Download Centre, where you will find more articles, white papers and interviews regarding this topic: http://bit.ly/automotive-doors------------------------------------------------------------------------------------------------------------------- ---------- IQPC GmbH | Friedrichstr. 94 | D-10117 Berlin, Germany t: +49 (0) 30 2091 3330 | f: +49 (0) 30 2091 3263 | e: eq@iqpc.de | w: www.iqpc.de Visit IQPC for a portfolio of topic-related events, congresses, seminars and conferences: www.iqpc.de

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